EP4069062A1 - Stimulateur implantable doté d'un réseau d'électrodes et d'un substrat conformable - Google Patents

Stimulateur implantable doté d'un réseau d'électrodes et d'un substrat conformable

Info

Publication number
EP4069062A1
EP4069062A1 EP20829652.5A EP20829652A EP4069062A1 EP 4069062 A1 EP4069062 A1 EP 4069062A1 EP 20829652 A EP20829652 A EP 20829652A EP 4069062 A1 EP4069062 A1 EP 4069062A1
Authority
EP
European Patent Office
Prior art keywords
substrate
layer
implantable stimulator
electrode
stimulator according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20829652.5A
Other languages
German (de)
English (en)
Inventor
Hubert Martens
Daniël SCHOBBEN
Maartje VAN DER ZALM
Stijn BOERE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Salvia Bioelectronics BV
Original Assignee
Salvia Bioelectronics BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US16/703,706 external-priority patent/US11318319B2/en
Priority claimed from NL2025268A external-priority patent/NL2025268B1/en
Application filed by Salvia Bioelectronics BV filed Critical Salvia Bioelectronics BV
Priority claimed from PCT/IB2020/061474 external-priority patent/WO2021111371A1/fr
Publication of EP4069062A1 publication Critical patent/EP4069062A1/fr
Pending legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B5/00—Measuring for diagnostic purposes; Identification of persons
    • A61B5/0002—Remote monitoring of patients using telemetry, e.g. transmission of vital signals via a communication network
    • A61B5/0031—Implanted circuitry
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B5/00—Measuring for diagnostic purposes; Identification of persons
    • A61B5/40—Detecting, measuring or recording for evaluating the nervous system
    • A—HUMAN NECESSITIES
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    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B5/00—Measuring for diagnostic purposes; Identification of persons
    • A61B5/68—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient
    • A61B5/6846—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient specially adapted to be brought in contact with an internal body part, i.e. invasive
    • A61B5/6847—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient specially adapted to be brought in contact with an internal body part, i.e. invasive mounted on an invasive device
    • A61B5/686—Permanently implanted devices, e.g. pacemakers, other stimulators, biochips
    • A—HUMAN NECESSITIES
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    • A61B5/68—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient
    • A61B5/6846—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient specially adapted to be brought in contact with an internal body part, i.e. invasive
    • A61B5/6847—Arrangements of detecting, measuring or recording means, e.g. sensors, in relation to patient specially adapted to be brought in contact with an internal body part, i.e. invasive mounted on an invasive device
    • A61B5/6861—Capsules, e.g. for swallowing or implanting
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    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
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    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
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    • A61N1/0472—Structure-related aspects
    • A61N1/0476—Array electrodes (including any electrode arrangement with more than one electrode for at least one of the polarities)
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    • A61N1/36082—Cognitive or psychiatric applications, e.g. dementia or Alzheimer's disease
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    • A61N1/32—Applying electric currents by contact electrodes alternating or intermittent currents
    • A61N1/36—Applying electric currents by contact electrodes alternating or intermittent currents for stimulation
    • A61N1/3605—Implantable neurostimulators for stimulating central or peripheral nerve system
    • A61N1/3606—Implantable neurostimulators for stimulating central or peripheral nerve system adapted for a particular treatment
    • A61N1/36114—Cardiac control, e.g. by vagal stimulation
    • A61N1/36117—Cardiac control, e.g. by vagal stimulation for treating hypertension
    • A—HUMAN NECESSITIES
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    • A61N1/32—Applying electric currents by contact electrodes alternating or intermittent currents
    • A61N1/36—Applying electric currents by contact electrodes alternating or intermittent currents for stimulation
    • A61N1/372—Arrangements in connection with the implantation of stimulators
    • A61N1/375—Constructional arrangements, e.g. casings
    • A—HUMAN NECESSITIES
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    • A61N1/18—Applying electric currents by contact electrodes
    • A61N1/32—Applying electric currents by contact electrodes alternating or intermittent currents
    • A61N1/36—Applying electric currents by contact electrodes alternating or intermittent currents for stimulation
    • A61N1/372—Arrangements in connection with the implantation of stimulators
    • A61N1/375—Constructional arrangements, e.g. casings
    • A61N1/3758—Packaging of the components within the casing
    • A—HUMAN NECESSITIES
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    • A61N1/36—Applying electric currents by contact electrodes alternating or intermittent currents for stimulation
    • A61N1/372—Arrangements in connection with the implantation of stimulators
    • A61N1/378—Electrical supply
    • A61N1/3787—Electrical supply from an external energy source
    • A—HUMAN NECESSITIES
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    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2420/00—Materials or methods for coatings medical devices
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    • A—HUMAN NECESSITIES
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Definitions

  • the present disclosure relates to an implantable stimulator, for providing electrical stimulation to human or animal tissue, having an electrode array located along a conformable portion of a substrate, In particular, it relates to an implantable stimulator having an encapsulation layer at least partially covering a portion of the substrate. It also relates to a method of manufacturing an implantable stimulator.
  • Implantable electrical stimulation systems may be used to deliver electrical stimulation therapy to patients to treat a variety of symptoms or conditions such as headaches, lower back pain and incontinence.
  • a stimulator typically comprising a therapeutic lead (a lead comprises electrodes and electrical connections), to provide electrical stimulation to one or more precise locations within a body - in many cases, precisely aligning the stimulation electrodes during implantation may be difficult due to the curvature of tissues and anatomical structures.
  • a mismatch in curvature of the electrode section of a lead may create unexpected and/or unpredictable electrical resistance between one or more electrodes and the underlying tissue.
  • repeated movement of the relevant areas of the body may even worsen the mismatch.
  • a particular problem with subcutaneous implants is that even small differences in flexibility between the implant and surrounding tissue may affect patient comfort, and can cause irritation of the overlying skin. This is a particular problem with sub-cutaneous implants.
  • neurostimulation leads in the craniofacial region is associated with skin erosion and lead migration.
  • the cylindrical shape and associated thickness of state-of-the-art leads results in the lead eroding through the skin or results in the lead being displaced so that the electrodes no longer cover the targeted nerves.
  • Implantable active devices require a protection method to protect the implant electronics from bodily fluids present in human or animal bodies.
  • Bodily fluids typically contain ions that may cause electrochemical reactions, like corrosion, in the presence of an electric current. Encapsulation is thus a critical component for the design of a medical device - it acts as a barrier between these ionic fluids and critical electronic/electric interfaces to reduce and/or prevent degradation of the implant electronics.
  • Polyimides are popular for use as a substrate material for the microfabrication of electronics, and attempts have been made to encapsulate polyimides with silicone rubber encapsulants, such as polydimethylsiloxane rubber (PDMS).
  • silicone rubber encapsulants such as polydimethylsiloxane rubber (PDMS).
  • PDMS polydimethylsiloxane rubber
  • the degree of bonding was increased by functionalizing the surfaces of the PDMS and polyimide substrates with mercaptosilanes and epoxysilanes, respectively, for the formation of a thiolepoxy bond in the click reaction. It was also increased by functionalizing one or both surfaces with mercaptosilane and introducing an epoxy adhesive layer between the two surfaces.
  • PDMS can be substantially biocompatible, causing minimal tissue reaction while having a relative long period of biostability, it still has a relatively high permeability to moisture which can lead to degradation of the implant electronics. Many other encapsulants with a lower degree of moisture permeability may have a lower degree of biocompatibility.
  • LCP’s Liquid Crystal Polymers
  • the disclosed embodiments may include one or more of the features described herein.
  • An implantable stimulator comprising: a substrate, the substrate comprising a first and second surface, wherein a thickness of the substrate is defined by the first and second surfaces; a pulse generator configured to generate at least one stimulation pulse; and an electrode array comprising at least two electrodes located along a conformable portion of the substrate; the implantable stimulator further comprising: a plurality of electrical interconnections electrically coupling the pulse generator to the at least two electrodes of the electrode array; wherein the plurality of electrical interconnections are positioned between the first and second surfaces of the substrate; wherein the thickness of the substrate along the conformable portion is equal to or less than 0.5 millimeters.
  • the products and methods described herein provide a high degree of conformability as well as high degree of configurability.
  • a higher degree of conformability may increase the comfort for the user.
  • the thickness of the conformable portion is equal to or less than 0.3 millimeters, or equal to or less than 0.2 millimeters, or equal to or less than 0.1 millimeters.
  • the substrate comprises a further portion along which the pulse generator s located, the implantable stimulator further comprising an encapsulation layer at least partially covering the further portion of the substrate.
  • the further portion of the substrate and pulse generator are at least partially embedded in one or more flexible bio-compatible encapsulation layers.
  • Encapsulation may improve the reliability and/or lifetime of the implantable substrate.
  • the implantable stimulator further comprises an adhesion layer adjacent to at least part of the substrate.
  • the substrate comprises more than one adjacent substrate layer and the adhesion layer is between substrate layers.
  • One or more adhesion layers may improve the performance of the encapsulation. This may also improve the reliability and/or lifetime of the implantable substrate. By providing a multilayer, thinner leads may be used, adding to the flexibility and therefore improving conformability.
  • the adhesion layer comprises a ceramic material.
  • a ceramic material may be advantageous comprised in an adhesion layer between a substrate material and encapsulant material.
  • the ceramic material is selected from the group consisting of: Hf02, A1203, Ta203, SiC, Si3N4, Ti02, and any combination thereof.
  • the adhesion layer comprises at least one first layer comprising Hf02 and at least one second layer adjacent to the at least one first layer and comprising A1203. Additionally or alternatively, the adhesion layer comprises at least one first layer comprising Ta203 and at least one second layer adjacent to the at least one first layer and comprising A1203. Additionally or alternatively, the adhesion layer comprises at least one first layer comprising Ti02 and at least one second layer adjacent to the at least one first layer and comprising A1203.
  • a ceramic portion of the adhesion layer has an average thickness in the range of 25nm to 200nm.
  • the adhesion layer comprises a ceramic portion that is applied using atomic layer deposition (ALD).
  • ALD atomic layer deposition
  • the thickness of the stimulator along the further portion is equal to or less than 5 millimeters, or equal to or less than 4 millimeters, or equal to or less than 3 millimeters.
  • the plurality of electrical interconnections are positioned between the first and second surfaces of the substrate using metallization. Additionally or alternatively, the plurality of electrical interconnections are comprised in one or more conductive interconnection layers, the one or more conductive interconnection layers being comprised between two adjacent polymeric substrate layers.
  • a method of manufacturing an implantable stimulator comprising: providing a substrate, the substrate comprising a first surface and a second surface, wherein a thickness of the substrate is defined by the first and second surfaces; providing a pulse generator, the pulse generator being configured to generate at least one stimulation pulse; locating an electrode array comprising at least two electrodes along a conformable portion of the substrate; and depositing or electro-plating onto the substrate a plurality of electrical interconnections; electrically coupling the pulse generator to the at least two electrodes of the electrode array; wherein the thickness of the substrate along the conformable portion is equal to or less than 0.5 millimeters.
  • the pulse generator is provided along a further portion of the substrate, the method further comprising at least partially covering the further portion of the substrate with an encapsulation layer.
  • the stimulator further comprises: an encapsulation layer at least partially covering the substrate; and an adhesion layer between the encapsulation layer and the substrate in at least one location.
  • the encapsulation layer covers at least part of the conformable portion of the substrate, and the adhesion layer is between the encapsulation layer and the at least part of the conformable portion of the substrate.
  • Such products and associated methods described herein provide improved bonding to improve resistance to fluid ingress in implantable devices comprising flexible substrates.
  • the encapsulant/adhesion layer may be optimized to protect a surface of many types of substrates. If the substrate is configured and arranged to be substantially flexible, the substrate may have a high degree of conformability. The high degree of adhesion of the encapsulant/adhesion layer allows the flexible encapsulant layer to provide a high degree of ingress protection for one or more surfaces of a flexible substrate.
  • One or more regions of a substrate surface may be protected by an encapsulant/adhesion layer.
  • Each encapsulant/adhesion layer may be optimized separately or together to a predetermined degree.
  • the conformable portion of the substrate comprises a liquid crystal polymer (LCP).
  • LCP liquid crystal polymer
  • the substrate comprises a further portion along which the pulse generator is located, the encapsulation layer at least partially covering the further portion of the substrate.
  • the encapsulation layer comprises a polymer and/or Polydimethylsiloxane (PDMS).
  • PDMS Polydimethylsiloxane
  • the adhesion layer appears to show significantly higher stability in ionic media, thereby providing relatively longer protection in case of any delamination or water permeation through the encapsulant.
  • a PDMS may further contribute to longer-lasting adhesion and defect reduction due to flowing in-between any defects and crevices in the adhesion layer - in particular, a PDMS with a relatively low viscosity may provide an even higher degree of defect reduction.
  • the ceramic materials Hf02, A1203, Ta203, SiC, Si3N4, Ti02, and any combination thereof, may be advantageously used as in an adhesion layer for a PDMS encapsulant layer.
  • a method of manufacturing an implantable stimulator comprising: providing a substrate, the substrate comprising a first surface and a second surface, wherein a thickness of the substrate is defined by the first and second surfaces; - providing a pulse generator, the pulse generator being configured to generate at least one stimulation pulse; locating at least two electrodes along a conformable portion of the substrate; depositing or electro-plating onto the substrate a plurality of electrical interconnections electrically coupling the pulse generator to the at least two electrodes; applying an adhesion layer at least partially covering the substrate; and applying an encapsulation layer over the adhesion layer; wherein the thickness of the substrate along the conformable portion is equal to or less than 0.5 millimeters.
  • the adhesion layer is applied using atomic layer deposition (ALD).
  • ALD atomic layer deposition
  • the pulse generator is provided along a further portion of the substrate, wherein the adhesion layer and encapsulation layer are applied to at least partially cover the further portion of the substrate .
  • FIG. 1 A is a transverse view of a first implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. IB is a top view of a first implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 1C is a bottom view of a first implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 2A is a transverse view of a second implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 2B is a top view of a second implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 2C is a bottom view of a second implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 3 A is a transverse view of a third implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 3B is a top view of a third implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 3C is a bottom view of a third implementation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 4A is a first view of alternative electrode configurations of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 4B is a second view of alternative electrode configurations of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 4C is a third view of alternative electrode configurations of an implantable 30 stimulator consistent with certain embodiments of the present invention.
  • FIG. 5 presents locations of nerves in the anterior portion of a human head that may be treated through operation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 6 presents locations of nerves in the posterior portion of a human body that may be treated through operation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 7 presents locations of nerves in a human body that may be treated through operation of an implantable stimulator consistent with certain embodiments of the present invention.
  • FIG. 8A and 8B depict Electrochemical Impedance Spectroscopy (EIS) as Bode plot results of FIG. 8 A: impedance magnitude and FIG. 8B: phase angle for three samples.
  • EIS Electrochemical Impedance Spectroscopy
  • FIG. 8C and 8D depict EIS results at 10 2 Hz over four hundred and fifty days of soaking as FIG. 8C: impedance magnitude and FIG. 8D: phase angle for four samples.
  • FIG. 9 presents measurement results comparing the average pull force, dry and after soaking, of LCP coated with PDMS using different processes.
  • FIG. 10 depicts a cross-section through a test sample.
  • FIG. 11 A, FIG. 11B and FIG. 11C depict cross-sections through improved implantable electrical devices.
  • FIG. 12A and FIG. 12B depict cross-sections through improved implantable medical devices comprising an improved implantable electrical device, and one or more electrodes.
  • the terms “a” or “an”, as used herein, are defined as one or more than one.
  • the term “plurality”, as used herein, is defined as two or more than two.
  • the term “another”, as used herein, is defined as at least a second or more.
  • the terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language).
  • the term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
  • ranges are used herein in shorthand, so as to avoid having to list and describe each and every value within the range. Any appropriate value within the range can be selected, where appropriate, as the upper value, lower value, or the terminus of the range.
  • FIG. 1 A, IB & 1C depict longitudinal cross-sections through a first embodiment 100 of an implantable stimulator comprising:
  • a pulse generator 500 (only depicted in FIG. IB and 1C) for generating at least one electrical treatment stimulation pulse
  • the substrate 300 comprises one or more adjacent polymeric substrate layers and has a first 310 and a second 320 planar (outer) surface.
  • the implantable stimulator 100 also comprises:
  • an electrode array 200, 400 proximate the distal end, having at least one electrode of a first 200a, 200b type and at least one electrode of a second type 400a, 400b.
  • the electrodes 200, 400 are comprised in the first 310 or second 320 surface, and each is configurable for transferring treatment energy, in use, to (as a stimulation electrode) and/or from (as a return electrode) human or animal tissue.
  • an array may be considered a systematic arrangement of two or more electrodes 200a, 200b, 400a,
  • ID, 2D or 3D arrays may be provided. Optionally, they may be arranged in rows and/or columns.
  • the implantable stimulator 100 further comprises:
  • one or more electrical interconnections 250 between the pulse generator 500 and the first 200a, 200b and the second 400a, 400b electrodes, for transferring electrical energy as one or more electrical treatment stimulation pulses to the coupled first electrodes 200a, 200b and/or the second electrodes 400a, 400b.
  • the one or more electrical interconnections 250 are comprised (or positioned) between the first surface 310 and the second 320 surfaces.
  • a plurality of electrical interconnections 250 is considered to be two, or more than two, electrical interconnections 250.
  • the conformability of the electrode array 200, 400 is determined to a high degree by the one or more of the following:
  • an implantable electrode array 200, 400 may be provided which is foil-like (or film-like) and highly conformable.
  • the conformable portion of the foil-like substrate 300 is preferably elongated along the longitudinal axis 600, having a tape-like shape, allowing the pulse generator 500 to be disposed (or located) further away from the position of the electrodes 200, 400.
  • the first 310 and second 320 surfaces are disposed along substantially parallel transverse planes 600, 700. As depicted in FIG.
  • the first surface 310 lies in a plane comprising the longitudinal axis 600 and a first transverse axis 700 - the first transverse axis 700 is substantially perpendicular to the longitudinal axis 600.
  • the plane of the first surface 310 is substantially perpendicular to the plane of the cross-section drawing (substantially perpendicular to the surface of the paper).
  • the conformable portion of the foil-like substrate 300 has a maximum thickness of 0.5 millimeter or less, proximate the first 200a, 200b and second 400a, 400b electrodes, the thickness being defined by the first 310 and second surfaces 320 - it may be determined by a perpendicular distance between corresponding points on the first 310 and second planar surfaces 320. This is preferably determined when the substrate 300 conforms to a planar surface.
  • the foil-like substrate 300 has a thickness or extent along a second transverse axis 750 - this second transverse axis 750 is substantially perpendicular to both the longitudinal axis 600 and the first transverse axis 700 - it lies in the plane of the drawing (along the surface of the paper) as depicted.
  • the first surface 310 is depicted as an upper surface and the second surface 320 is depicted as a lower surface.
  • the thickness may therefore be determined by a perpendicular distance along the second transverse axis 750 between corresponding points on the first 310 and second planar surfaces 320.
  • the maximum thickness of the conformable portion of the foil-like substrate 300 proximate the first 200a, 200b and second 400a, 400b electrodes is 0.5mm or less, preferably 0.3 millimeters or less, even more preferably 0.2 millimeters or less, yet more preferably 0.1 millimeters or less.
  • the lower the maximum thickness in other words, the thinner the substrate
  • the higher the degree of conformance in general, the lower the maximum thickness (in other words, the thinner the substrate), the higher the degree of conformance.
  • a higher maximum thickness may be preferred to improve mechanical strength.
  • the longitudinal axis 600 extends from the proximal end (not depicted in FIG.
  • the second transverse axis 750 extends from bottom to top as depicted.
  • the conformable portion of the foil-like substrate 300 may be configured and arranged as a multilayer - it comprises two or more adjacent polymeric substrate layers secured to each other, and having the first 310 and second 320 planar surface.
  • the one or more electrical interconnections 250 are also comprised (or positioned) between the first 310 and second 320 planar surfaces.
  • regions where an interconnection 250 is sandwiched between two polymeric substrate layers may be regions where an interconnection 250 is sandwiched between two polymeric substrate layers (appears as a multilayer in a longitudinal cross-section), adjacent to regions where the substrate comprises two adjacent substrate layers.
  • a substrate comprising two or more polymeric substrate layer may be modified (physically and/or chemically), such that it appears to be one layer of polymeric substrate.
  • polymeric substrate layers are selected for suitability to be conformable, and to comprise the one or more electrical interconnections 250.
  • the polymeric substrate materials are also biocompatible and durable, such as a material selected from the group comprising silicone rubber, siloxane polymers, polydimethylsiloxanes, polyurethane, polyether urethane, polyetherurethane urea, polyesterurethane, polyamide, polycarbonate, polyester, polypropylene, polyethylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polysulfone, cellulose acetate, polymethylmethacrylate, polyethylene, and polyvinylacetate.
  • Suitable polymer materials including LCP (Liquid Crystal Polymer) films, are described in “Polymers for Neural Implants”, Hassler, Boretius, Stieglitz, Journal of Polymer Science: Part B Polymer Physics, 2011, 49, 18-33 (DOI 10.1002/polb.22169), In particular, Table 1 is included here as reference, depicting the properties of Polyimide (UBE U-Varnish-S), Parylene C (PCS Parylene C), PDMS (NuSil MED- 1000), SU-8 (MicroChem SU-8 2000 & 3000 Series), and LCP (Vectra MT1300).
  • Conformable foil-like substrates 300 are configured to follow the contours of the underlying anatomical features very closely by being flexible. Very thin foil-like substrates 300 have the additional advantage that they have increased flexibility.
  • the polymeric substrate layers comprise an LCP, Parylene and/or a Polyimide.
  • LCP are chemically and biologically stable thermoplastic polymers which allow for hermetic sensor modules having a small size and low moisture penetration.
  • an LCP may be thermoformed allowing complex shapes to be provided.
  • Very thin (and subsequently very conformable) and very flat (highly planar) layers of an LCP may be provided.
  • a suitable laser may also be used for cutting.
  • a conformable foil-like substrate 300 of LCP may have a thickness (extent along the second transverse axis 750) in the range 50 microns (um) to 720 microns (um), preferably 100 microns (um) to 300 microns (um). In an exemplary embodiment, values of 150 um (micron), lOOum, 50um, or 25um may be provided.
  • the foil-like surface 300 When conforming to a substantially planar surface, the foil-like surface 300 is substantially comprised in a plane with a transverse extent substantially perpendicular to the longitudinal axis 600, wherein the planar width may be determined by a perpendicular distance between corresponding points on outer surfaces edges of the planar foil-like substrate 300 along the transverse extent. As depicted, this is along the first transverse axis 700.
  • electrode 200, 400 widths of 2 mm to 20 mm may be provided using LCP.
  • LCP films have mechanical properties similar to steel. This is important as implantable substrates 300 should be strong enough to be implanted, strong enough to be removed (explanted) and strong enough to follow any movement of the neighboring anatomical features and/or structures without deteriorating.
  • LCP belongs to the polymer materials with the lowest permeability for gases and water. LCP’s can be bonded to themselves, allowing multilayer constructions with a homogenous structure.
  • polyimides are thermoset polymers, which require adhesives for the construction of multilayer portions with electrode arrays.
  • Polyimides are thermoset polymer material with high temperature and flexural endurance.
  • an LCP may be used to provide a conformable substrate 300 as a multilayer - in other words, two or more adjacent polymeric substrate layers. In a non limiting example, these may be layers of 25 um (micron) thickness.
  • one or more electrical interconnections 250 may be provided (or positioned) between the first 310 and second 320 surfaces by metallization. These may be conductors embedded in the substrate 300 such as by having a single polymer layer and applying conductive material using suitable deposition techniques known from the semiconductor industry.
  • an interconnection layer may be provided using suitable techniques such as those from the semiconductor industry.
  • the polymeric substrate layers may also be considered adjacent when one of more adhesion layers are used between them. Examples of suitable adhesion materials and adhesion layers are described below in relation to FIG.
  • lamination may also be used to provide a substrate 300 with the desired physical and chemical properties, and/or to provide a convenient method of manufacture.
  • a substrate 300 may comprise three laminated polymer layers: two high temperature thermoplastic layers with a low-temperature layer (bond-ply) in between, and high-temperature layers towards the first surface 310 and second surface 320.
  • two layers of silicone may be provided as polymeric substrate layers: one layer of silicone is provided, metal is patterned on one of its outer surfaces, and a second layer of silicone is added over the metal patterning by jetting, over-molding, or spin-coating.
  • the electrical interconnections 250 may comprise one or more conductive materials, such as a metal, formed as required in one or more conductive elements: wire, strand, foil, lamina, plate, and/or sheet. They may be a substantially contiguous (one conductor). They may also comprise more than one conductor, configured and arranged to be, in use, electrically connected with each other - in other words, the one or more conductors are configured and arranged to be substantially electrically contiguous in use.
  • conductive materials such as a metal, formed as required in one or more conductive elements: wire, strand, foil, lamina, plate, and/or sheet. They may be a substantially contiguous (one conductor). They may also comprise more than one conductor, configured and arranged to be, in use, electrically connected with each other - in other words, the one or more conductors are configured and arranged to be substantially electrically contiguous in use.
  • the one or more electrical interconnections 250 may be comprised in one or more conductive interconnection layers 250, the one or more conductive interconnection layers being comprised (or positioned) between two adjacent polymeric substrate layers. As depicted in FIG. 1A, a plurality of interconnections may be provided at different dispositions (or depths or positions) between the first surface 310 and the second surface 320.
  • an interconnection 250 in the context of this disclosure is not configured or arranged to be, in use, in contact with human or animal tissue.
  • the one or more interconnections 250 are embedded (or covered) in one or more layers of a low conductance or insulating polymer, such as LCP. Additionally or alternatively, one or more encapsulation layers may be used.
  • One or more interconnection layers 250 may also be provided by metallization using techniques from the PCB (Printed Circuit Board) industry, such as metallization with a bio-compatible metal such as gold or platinum. Electro-plating may be used.
  • PCB printed Circuit Board
  • Electro-plating may be used.
  • Layers comprising LCP films are particularly suitable for metallization. These electrical interconnections 250 and/or interconnect layers 250 are configured to transfer electrical energy as one or more electrical treatment stimulation pulses from the pulse generator 500 to the coupled first electrodes 200a, 200b and/or the second electrodes 400a, 400b.
  • suitable polymeric substrate materials such as an LCP film, allows the conformable portions of the foil-like (or film-like) substrate 300 and electrode array 200, 300 to have a high width -to-height ratio, providing a bio-compatible electronic foil (or film), or bio-electronic foil (or film).
  • the ratio of maximum planar width to maximum thickness proximate the first 200a, 200b and second 400a, 400b electrodes may be 7:1 or higher, preferably 10:1 or higher, more preferably 15:1 or higher, yet more preferably 30:1 or higher, even more preferably 50:1 or higher.
  • Ratios of 100: 1 or higher may also be advantageous, and may be provided using one or more mechanically strong substrate layers of an LCP film, with a width of approximately 20mm and a thickness of approximately 0.2 mm. This provides a high degree of flexibility, and therefore also a high degree of conformability. Additional measures may also be taken to increase the degree of conformability in the first transverse direction 700, such as varying the width of the substrate, adding one or more undulations and/or providing bending points.
  • the width when using a single row of electrodes 200, 400 and/or electrodes 200, 400 with a smaller width, the width may be four mm with a thickness of approximately 0.2mm - this is a ratio of approximately 20: 1.
  • a portion of the substrate proximate the pulse generator 500 greater extents may be required which further depend, to a high degree, on the dimensions of the electronic components used a width of twenty mm and a thickness of three mm. This is a ratio of approximately 6.67: 1.
  • the distal end (or distal portion) of the conformable foil like substrate 300 comprises:
  • each electrode of the first type 200a, 200b is proximate an electrode of the second type 400a, 400b and comprised in the same surface 310.
  • the foil-like substrate 300 comprises an electrical interconnection 250 between each electrode 200a, 400a, 200b, 400b and the pulse generator.
  • each electrical interconnection 250 is configured and arranged such that each electrode 200a, 400a, 200b, 400b is electrically connected substantially independently - consequently, one of the operating modes available by suitably configuring the pulse generator 500 is substantially independent operation.
  • the pulse generator 500 may be configured using one or more hardware, firmware and/or software parameters.
  • FIG. 1 A Although depicted in FIG. 1 A as individual connections 250 at different distances (or positions) between the first 310 and second 320 surfaces, the skilled person will also realize that the same interconnections may be provided by a suitably configured interconnections 250 (or an interconnection layer 250) at approximately the same distance (or position) between the first 310 and second 320 surfaces, similar to the embodiment depicted in FIG. 3B, and described below.
  • “Comprised in” the first 310 or second 320 surface means that the electrodes 200a, 400a, 200b, 400b are relatively thin (such as when the substrate is arranged to conform to a substantially planar surface, it may have an extent along the second transverse axis of 20 to 50 microns or less. Thinner electrodes may be also be used to further increase the degree of conformability, such as 1 micron or less), and attached to (or at least partially embedded in) the surface.
  • the electrodes 200, 400 may comprise a conductive material such as gold, platinum, platinum black, TiN, IrC , iridium, and/or platinum/iridium alloys and/or oxides. Conductive polymers, such as Pedot, may also be used. Preferably, bio compatible conductive materials are used. PCB/metallization techniques may be used to manufacture them on or in the first 310 and/or second 330 surfaces of the one or more polymeric substrate layers.
  • Thicker metal layers are generally preferred over thinner metal layers for electrodes 200a, 200b, 400a, 400b because they can be subjected to bodily substances that may dissolve the metal.
  • thicker metal layers typically increase rigidity (reduce conformability) proximate the thicker layer.
  • the stimulator 100 may be implanted by first creating a subcutaneous tunnel and/or using an implantation tool.
  • the high degree of conformability may make successful implantation more difficult.
  • the electrode positions may be found later to be incorrect due to misalignment, lead migration during implantation, or lead migration after transplantation.
  • At least the distal end comprising the electrode array 200, 400, is implanted. However, it may be advantageous to implant the stimulator 100.
  • the stimulator electrodes should be positioned sufficiently close to the nerve to be stimulated. But nerve pathways may not always be clearly visible to the professional performing the implantation, and the disposition and path of the nerve pathways vary greatly from person-to-person.
  • any difference in functionality is determined in this implementation mainly by the configuration (one or more hardware, firmware and/or software parameters) of the pulse generator 500. There may be a smaller influence on the electrical properties due to the arrangement and routing of the interconnections 250.
  • One or more coupled electrodes of the same type 200a, 200b or 400a, 400b may be operated substantially the same by suitable configuration of the pulse generator 500 - in other words, the stimulation energy applied to the electrodes 200, 400 is substantially the same at substantially the same time instance (usually measured as a voltage, a current, a power, a charge, or any combination thereof). This may also be used to anticipate and/or correct for a misalignment and/or lead migration - this is advantageous as it allows the configuration to be performed at least partially using software.
  • two or more electrodes 200, 400 may be configured and arranged using one or more parameters of the pulse generator 500 as a stimulation electrode or a return electrode. This may provide a higher degree of configurability as it only becomes necessary to implant the substrate 300 such that at least two of the electrodes are proximate the desired stimulation location.
  • the electrodes of the first type 200a, 200b are nominally configured and arranged to be operated as a stimulation electrode.
  • the electrodes of the second type 400a, 400b are nominally configured to be operated as a return electrode - each is configured to provide, in use, an electrical return for one or more stimulation electrode 200a, 200b.
  • the electrical return 400a, 400b closes the electrical circuit. It may also be similarly configured to provide an electrical ground for a corresponding electrical energy source.
  • one or more stimulation electrodes 200a, 200b may be provided in such a stimulator 100.
  • the number, dimensions and/or spacings of the stimulating electrodes 200a, 200b may be selected and optimized depending on the treatment.
  • each stimulation electrode 200a, 200b may provide:
  • a selection may be made of one or two electrodes 200a, 200b proximate the tissues where the effect is to be created.
  • Two or more stimulation electrodes 200a, 200b may be made active at substantially the same time if stimulation over a larger area is required and/or at a location between the active stimulation electrodes 200a, 200b.
  • a stimulation electrode 200a, 200b may have dimensions in the order of six to eight mm along the longitudinal axis 600, and three to five mm along the first transverse axis 700, so approximately 18 to 40 square mm (mm 2 ).
  • a foil-like substrate 300 suitable for an implantable stimulator, may comprise up to twelve stimulation 200a, 200b and return 400a, 400b electrodes over a length of 15cm to allow for a correction for misalignment, or to simply allow the specialist to select the most effective stimulation location.
  • FIG. IB depicts a view of the second surface 320 of the implantable distal end (or portion) of the foil-like substrate 300 depicted in FIG. 1 A.
  • the second surface 320 is depicted in the plane of the paper, lying along the longitudinal axis 600 (depicted from bottom to top) and in the first transverse axis 700 (depicted from left to right).
  • the second transverse axis 750 extends into the page.
  • the first surface 310 is not depicted in FIG. IB, but lies at a higher position along the second transverse axis 750 (into the page), and is also substantially parallel to the plane of the drawing.
  • the foil-like substrate 300 is arranged to conform to a substantially planar surface.
  • the pulse generator 500 may be disposed (or positioned) between the second 320 surface and the first 310 surface. In FIG. IB and 1C, it is depicted with dotted lines. Alternatively, the pulse generator 500 may be at least partially disposed on the first surface 310 or on the second surface 320. Alternatively, the pulse generator 500 may be at least partially embedded in the first surface 310 or in the second surface 320.
  • the maximum thickness may be optimized. Components may be thinned to minimize the thickness. If the substrate 300 is configured and arranged to be conformable and/or foil-like, the maximum thickness of the implantable stimulator 100 in a portion of the substrate proximate the pulse generator 500 may be five millimeters or less, preferably four millimeters or less, even more preferably three millimeters or less, the thickness being determined by a perpendicular distance between corresponding points on outer planar surfaces when the implantable stimulator 100 conforms to a substantially planar surface. Additional optional electrical components, such as an antenna, comprising a coil or dipole or fractal antenna, may also influence the thickness depending on the degree that they are embedded in the substrate.
  • an antenna comprising a coil or dipole or fractal antenna
  • the stimulator 100 and the foil-like substrate 300 extend along the first transverse axis 700 (considered the planar width of the stimulator 100 / foil-like substrate 300 when conforming to a substantially planar surface).
  • the planar width in a portion of the substrate proximate the pulse generator 500 may be greater than the planar width in another portion of the substrate proximate the electrodes 200a, 200b, 400a, 400b at the distal end (or portion) of the foil-like substrate 300.
  • the planar width proximate the pulse generator 500 may depend on the hardware and components used for the pulse generator 500 - typically, it is at least the width of the integrated circuit used for the pulse generator 500. Additional optional electrical components, such as an antenna comprising a coil or dipole or fractal antenna, may also influence the planar width.
  • the planar width proximate the electrodes 200a, 200b, 400a, 400b may depend on the conductors used for the electrodes 200a, 200b, 400a, 400b and the one or more interconnections 250. In an embodiment, the planar width is at least the width of the first electrode 200a, 200b or the second electrode 400a, 400b.
  • FIG. 1C depicts a view of the first surface 310 of the implantable distal end (or portion) of the foil-like substrate 300 depicted in FIG. 1 A and IB.
  • the first surface 310 is depicted in the plane of the paper, lying along the longitudinal axis 600 (depicted from bottom to top) and in the first transverse axis 700 (depicted from right to left).
  • the second transverse axis 750 extends out of the page. This is the view facing the animal or human tissue which is stimulated (in use).
  • the second surface 320 is not depicted in FIG. 1C, but lies at a lower position along the second transverse axis 750 (into the page), and is also substantially parallel to the plane of the drawing.
  • the foil-like substrate 300 is arranged to conform to a substantially planar surface.
  • the one or more interconnections 250 are disposed (or positioned) between the first 310 surface and the second 320 surface, as depicted in FIG. 1A. In FIG. 1C, they are depicted as dotted lines, representing the interconnections 250 (or suitably configured one or more interconnection layers 250) that have been provided for each of the electrodes 200a, 200b, 400a, 400b in this embodiment.
  • a single dotted line 250 is depicted between the pulse generator 500 and the electrodes 200, 400 to indicate, in embodiment 100, that the interconnections 250 are at approximately the same disposition along the first transverse axis 700.
  • the electrodes 200a, 200b, 400a, 400b each have a longitudinal extent (length) along the longitudinal axis 600 and a transverse extent (width) along the first transverse axis 700.
  • each electrode 200a, 200b, 400a, 400b may vary in shape, transverse cross-section, orientation and/or size (or extent), depending on the intended use and/or the desired degree of configurability.
  • the pulse generator 500 may be configured and arranged to provide, in use, electrical energy to the one or more coupled electrodes of the first type 200a, 200b with respect to the electrical return applied to the one or more coupled electrodes of the second type 400a, 400b.
  • the configurability of the stimulator 100 allows, before, during and/or after implantation of at least of the distal end (or portion) comprising the electrode array 200, 400, the operation of the one or more electrodes 200a, 200b, 400a, 400b to be determined and/or adapted. The operation may also be reconfigured one or more times during the period that the stimulator 100 is implanted to optimize and/or prolong treatment.
  • the pulse generator 500 may be initially configured to nominally operate 200a and 400a as respectively a stimulation / return electrode pair.
  • the pulse generator 500 may be alternatively configured, using one or more parameters, to nominally operate 200b and 400b as respectively a stimulation / return electrode pair.
  • the stimulator 100 may be further configured and arranged to switch the pulse generator 500 under predetermined and/or controlled conditions between these configurations. It may be convenient to further consider these configurations as a first and second electrode modes, and allow a user to select a mode as a preference and/or switch mode. Alternatively, the pulse generator 500 may switch modes under predetermined and/or controlled conditions.
  • pulse generator 500 may operate in:
  • first electrode mode wherein electrical stimulation energy is provided to one or more coupled electrodes of the first type 200a, 200b as one or more electrical treatment stimulation pulses, the one or more coupled electrodes of the second type 400a, 400b being configured to provide, in use, a corresponding electrical return for the one or more first electrodes 200a, 200b; or
  • the stimulator 100 may be further configured and arranged to switch the pulse generator 500 under predetermined and/or controlled conditions between these configurations or modes. Additionally or alternatively, a user may be allowed to select a mode as a preference and/or switch mode.
  • electrodes 200a, 200b, 400a, 400b may be configured to operate in more complex configurations, such as:
  • - 400a and 200a may be operated as respectively a stimulation / return electrode pair (reversing the original intended operation);
  • - 400b and 200b may be operated as respectively a stimulation / return electrode pair
  • two or more electrodes 200a, 200b, 400a, 400b may be operated substantially simultaneously as one or more stimulation electrodes;
  • one or more electrodes 200a, 200b, 400a, 400b may be operated as one or more return electrodes;
  • - electrode 400a operated as a stimulation electrode, in combination with electrode 200a and electrode 200b as return electrodes;
  • Electrode 400a and 200b operated as a stimulation electrode, in combination with electrode 200a and electrode 400b as a return electrode.
  • the shape, orientation, transverse cross-section, and/or size (or length) of one or more stimulation electrodes may be differently configured compared to one or more return electrodes.
  • a number of parameters and properties may be considered when configuring and arranging a portion of the foil-like substrate 300 proximate the electrode array 200, 400 for conformability, such as:
  • the materials comprised in the foil-like substrate 300 and their physical properties - the number and extent of interconnections 250 and/or interconnection layers 250 between the first surface 310 and second surface 320.
  • a conventional 0.2mm round lead with 1 cm long electrodes is estimated to result in an electrode with approximately 6 mm 2 electrode surface.
  • a thin substrate 300 with dimensions of 0.2 mm thick, and four mm wide may be configured and arranged to provide approximately 35 mm 2 electrode surface in the same length. It is estimated that this may reduce impedance by a factor of approximately 35/6, and reduce power consumption by approximately 35/6.
  • FIG. 2A, 2B and 2C depict longitudinal cross-sections through a second embodiment 101 of an implantable stimulator. It is similar to the first embodiment 100, depicted in FIG. 1A, IB and 1C except:
  • this embodiment comprises two electrodes in the first surface 310 - nominally an electrode of the first type 200a and nominally an electrode of the second type 400a. From proximal to distal end, the order depicted is 200a, 400a - in other words, an electrode of the first type 200a is proximate an electrode of the second type 400a in the first surface 310.
  • the distal end of the stimulator 101 also comprises two electrodes in the second surface 320 - a further electrode nominally of the first type 200b and a further electrode nominally of the second type 400b. From proximal to distal end, the order depicted is 200b, 400b - in other words, an electrode of the first type 200b is proximate an electrode of the second type 400b in the second surface 320.
  • the view of the second surface 320 depicts the two electrodes 200a, 400a comprised in that surface, and one or more interconnections 250 are depicted using a dotted line;
  • the view of the second surface 320 depicts the two electrodes 200b, 400b comprised in that surface, and one or more interconnections 250 are depicted using a dotted line;
  • the electrodes of the first type 200a, 200b are nominally configured and arranged to be operated as a stimulation electrode, and the electrodes of the second type 400a, 400b are nominally configured to be operated as a return electrode.
  • the implantable distal end of the foil -like substrate 300 may be “above” or “below” the targeted tissue such as “above” or “below” a nerve. This may be determined after implantation by attempting stimulation in each nominal configuration and observing and/or measuring the presence of neural stimulation.
  • each electrode 200a, 200b, 400a, 400b may be operated as one or more stimulation electrodes or operated as one or more return electrodes.
  • FIG. 3A, 3B and 3C depict longitudinal cross-sections through a third embodiment 102 of an implantable stimulator. It is similar to the second embodiment 101, depicted in FIG. 2 A, 2B and 2C except:
  • - interconnections 250 are disposed at approximately the same disposition along the second transverse axis 750, as depicted in FIG. 3A.
  • the lines 250 are hatched to indicate that they are not be depicted as being in the same longitudinal cross-section - there are interconnections 250 disposed at substantially different positions along the first transverse axis 700;
  • - interconnections 250 are disposed at substantially different dispositions along the first transverse axis 700, as depicted in FIG. 3B and 3C as two adjacent dashed lines between the electrode array 200, 400 and the pulse generator 500;
  • the first surface 310 comprises a first 200a and second 200b electrode nominally of the first type 200;
  • the second surface 320 comprises a first 400a and second 400b electrode nominally of the second type 400;
  • the electrodes of the first type 200a, 200b are nominally configured and arranged to be operated as a stimulation electrode, and the electrodes of the second type 400a, 400b are nominally configured to be operated as a return electrode.
  • stimulation / return electrode pair 200a / 400a for stimulating between the first surface 310 and second surface 320 proximate the location of this electrode pair;
  • each electrode 200a, 200b, 400a, 400b may be operated as one or more stimulation electrodes or operated as one or more return electrodes.
  • one or more electrodes of the same type 200a, 200b or 400a, 400b may be electrically connected to each other by suitably configuring the one or more interconnections 250. They will then be operated substantially the same. This may be used to anticipate and/or correct for a misalignment and/or lead migration as longitudinal positioning is less sensitive (a stimulation is provided over a greater longitudinal and or transverse extent).
  • FIG. 4 A depicts an implantable distal end of a further embodiment 103 of a stimulator. Similar to the distal end depicted in FIG. 1C, the first surface 310 comprises:
  • each electrode of the first type 200a, 200b is proximate an electrode of the second type 400a, 400b and comprised in the same surface 310.
  • FIG. 4A The distal end depicted in FIG. 4A is the same as that depicted in FIG. 1 A, except:
  • the electrodes 200, 400 are extended at angle to the longitudinal axis 600. This may reduce the sensitivity to longitudinal misalignment because the longitudinal locations over which tissue stimulation may be provided are increased.
  • the second surface 320 may similarly comprise two electrodes 200a, 200b of the first type and two electrodes 400a, 400b of the second type.
  • each electrode 200a, 200b, 400a, 400b may be operated as one or more stimulation electrodes or operated as one or more return electrodes.
  • FIG. 4B depicts an implantable distal end of a further embodiment 104 of a stimulator. Similar to the distal end depicted in FIG. 1C, the first surface 310 comprises four electrodes. However, in this embodiment 104, the first surface 310 comprises:
  • Electrodes 200a, 200b, 200c, 200d of a first type and an electrode 400 of a second type From proximal to distal end, the order depicted is 200a, 200b, 200c, 200d.
  • Transversely adjacent to the four electrodes of the first type 200 is an electrode of the second type 400, extending longitudinally to be adjacent to each electrode of the first type 200. Nominally, the electrodes of the first type 200 may be operated as one or more stimulation electrodes.
  • the electrode of the second type 400 may be nominally operated as a return electrode for one or more of the stimulation electrodes.
  • the second surface 320 may similarly comprise four electrodes 200a, 200b, 200c, 2003 of the first type and one adjacent and longitudinally extended electrode 400 of the second type.
  • each electrode 200a, 200b, 200c, 200d, 400 may be operated as one or more stimulation electrodes or operated as one or more return electrodes.
  • FIG. 4C depicts an implantable distal end of a further embodiment 105 of a stimulator. Similar to the distal end depicted in FIG. 4B, the first surface 310 comprises four electrodes 200a, 200b, 200c, 200d of a first type. However, in this embodiment 105, the first surface 310 further comprises four adjacent electrodes 400a, 400b, 400c, 400d of a second type. From proximal to distal end, the order depicted is 200a/400a, 200b/400b, 200c/400c, 200d/400d. Transversely adjacent to each of the four electrodes of the first type 200 is an electrode of the second type 400 at approximately the same disposition along the longitudinal axis 600.
  • the electrodes of the first type 200 may be operated as one or more stimulation electrodes.
  • the electrodes of the second type 400 may be nominally operated as a return electrode for one or more of the stimulation electrodes.
  • adjacent electrodes may be considered as a stimulation/return pair 200/400.
  • a 2x4 electrode array is provided - two along a transverse axis and four along the longitudinal axis.
  • the second surface 320 may similarly comprise four electrodes 200a, 200b, 200c, 200d of the first type and four adjacent electrodes 400a, 400b, 400c, 400d of the second type.
  • each electrode 200a, 200b, 200c, 200d, 400a, 400b, 400c, 400d may be operated as one or more stimulation electrodes or operated as one or more return electrodes. This may also reduce the sensitivity to a transverse misalignment.
  • the stimulator 100, 101, 102, 103, 104, 105 may further comprise:
  • an energy receiver configured and arranged to wirelessly receive energy from an associated energy transmitter when the associated energy transmitter is proximate; the pulse generator 500 being further configured and arranged to receive electrical energy from the energy receiver for its operation.
  • FIG. 5 and FIG. 6 depict configurations of nerves that may be stimulated using a suitably configured implantable distal end of stimulators 100, 101, 102, 103, 104, 105 to provide neurostimulation to treat conditions such as headaches or primary headaches.
  • FIG. 5 depicts the left supraorbital nerve 910 and right supraorbital nerve 920 which may be electrically stimulated using a suitably configured device.
  • FIG. 6 depicts the left greater occipital nerve 930 and right greater occipital nerve 940 which may also be electrically stimulated using a suitably configured device.
  • a suitable location is determined to provide the electrical stimulation required for the treatment.
  • Approximate implant locations for the distal part of the stimulation device comprising stimulation devices 100, 101, 102, 103, 104, 105 are depicted as regions:
  • location 810 for left supraorbital stimulation and location 820 for right supraorbital stimulation for treating chronic headache such as migraine and cluster.
  • Locations 830a, 840b for stimulation are located superior (“above”) to the (external) occipital protuberance inion.
  • these will be the approximate locations 810, 820, 830a/b, 840a/b for the implantable stimulator 100, 101, 102, 103, 104, 105.
  • a separate stimulation system may be used for each implant location. Where implant locations 810, 820, 830a/b, 840a/b are close together, or even overlapping, a single stimulation system may be configured to stimulate at more than one implant location 810, 820, 830a/b, 840a/b.
  • a plurality of stimulation devices 100, 101, 102, 103, 104, 105 may be operated separately, simultaneously, sequentially or any combination thereof to provide the required treatment.
  • FIG 7 depict further configurations of nerves that may be stimulated using a suitably configured improved implantable stimulator 100, 101, 102, 103, 104, 105 to provide neurostimulation to treat other conditions.
  • the locations depicted in FIG. 5 and FIG. 6 (810, 820, 830, 840) are also depicted in FIG. 7.
  • a suitable location is determined to provide the electrical stimulation required for the treatment.
  • Approximate implant locations for the part of the stimulation device comprising stimulation electrodes are depicted as regions:
  • Parkinson’s disease patients treating dystonia, obesity, essential tremor, depression, epilepsy, obsessive compulsive disorder, Alzheimer’s, anxiety, bulimia, tinnitus, traumatic brain injury, Tourette’s, sleep disorders, autism, bipolar; and stroke recovery
  • vagus nerve stimulation for treating epilepsy, depression, anxiety, bulimia, obesity, tinnitus, obsessive compulsive disorder, heart failure, Crohn’s disease and rheumatoid arthritis;
  • Other conditions that may be treated include gastro-esophageal reflux disease, an autoimmune disorder, inflammatory bowel disease and inflammatory diseases.
  • the conformability and reduced thickness of the substrate 100 and electrode array 200, 400 makes one or more implantable stimulators 100, 101, 102, 103, 104, 105 highly advantageous for the stimulation of one or more nerves, one or more muscles, one or more organs, spinal cord tissue, brain tissue, one or more cortical surface regions, one or more sulci, and any combination thereof.
  • the implantable stimulators 100, 101, 102, 103, 104, 105 described above in relation to FIG. 1 to FIG.4 may be generally described as embodiments configured and arranged for improved conformance.
  • the stimulator 100, 101, 102, 103, 104, 105 may be further modified. In a non-limiting example:
  • a portion of the foil-like substrate 300 and pulse generator 500 may be embedded in one or more flexible bio-compatible encapsulation layers, such as those described below. These layers may comprise: a Liquid Crystal Polymer (LCP), a Polydimethylsiloxane (PDMS), a silicone polyurethane, a Polyimide, a parylene, a biocompatible polymer, a biocompatible elastomer, and any combination thereof.
  • LCP Liquid Crystal Polymer
  • PDMS Polydimethylsiloxane
  • silicone polyurethane such as those described below.
  • the implantable electrical devices 1100, 1101, 1102 described below in relation to FIG. 8 to FIG.12 may be generally described as embodiments configured and arranged for improved encapsulation. As described below, they may be comprised in an implantable medical device 1110, 1111 configured and arranged to provide a degree of stimulation.
  • FIG. 11 A depicts a cross-section through an improved implantable electrical or electronic device 1100. It comprises:
  • a substrate 1400 having a first surface 1410 and one or more electrical conductors 1210.
  • the substrate 1400 may be substantially biocompatible - however, the use of one or more encapsulation layers 1310 may allow substrates 1400 and electrical conductors 1210 which are not biocompatible, partially biocompatible, or significantly biocompatible, to be used.
  • the degree of biocompatibility of a material or layer may be determined by measuring the degree of tissue reaction and the length of period during which it is considered biostable. A low degree of tissue reaction and/or long period of biostability indicates a high degree of biocompatibility.
  • the substrate 1400 is further configured and arranged to be substantially flexible - in other words, the substrate is pliant or flexible or compliant (or conformable) to a substantial degree.
  • the degree of flexibility may be adapted using parameters, such as:
  • the degree of flexibility may be adapted using parameters described above for the substrate 300 described in relation to FIG. 1 to FIG. 4.
  • the one or more electrical conductors 1210 are depicted very schematically - they may be conductors embedded in or deposited onto the substrate 1400 - for example, by having a single polymer layer and applying conductive material using suitable deposition techniques known from the semiconductor industry.
  • the one or more conductors 1210 such as a metal, may be formed as required - for example, in one or more conductive elements: wire, strand, foil, lamina, plate, and/or sheet.
  • the one or more conductors may be positioned between the outer surfaces of the substrate 1400;
  • the device 1100 further comprises:
  • a first biocompatible encapsulation layer 1310 comprising a polydimethylsiloxane (PDMS) rubber
  • a ceramic should be considered as an advanced ceramic and/or an industrial ceramic, providing a relatively high degree of thermal stability, wear-resistance and resistance to corrosion.
  • the most suitable ceramic materials are those with a high degree of adhesion to the encapsulant layer and/or substrate, and capable of being applied in a relatively uniform coating to provide a relatively low degree of permeability to moisture.
  • a ceramic material in this context may be an inorganic, non-metallic or metallic, often crystalline oxide, nitride or carbide material. Some elements, such as carbon or silicon, are also considered ceramics.
  • a non-metallic ceramic may comprise both non-metallic and metallic elements.
  • the first adhesion layer 1510 may be substantially biocompatible - however, the use of one or more encapsulation layers 1310 may allow one or more adhesion layers 1510 which are not biocompatible, partially biocompatible, or significantly biocompatible, to be used.
  • the first adhesion layer 1510 and the first encapsulation layer 1310 are configured and arranged to resist the ingress of fluids from a human or animal body into at least a portion of the first surface 1410. The configuration and arrangement are further described below.
  • the extent of the adhesion/encapsulation layer 1510/1310 in this cross-section may be less than the extent of the substrate 1400.
  • the extent of the adhesion/encapsulation layer 1510/1310 may be larger than, equal to or less than the extent of the substrate 1400.
  • a “larger than” embodiment for the adhesion and encapsulation layers is depicted in FIG. 11C.
  • Further “less than” embodiments for the adhesion and encapsulation layers are depicted in FIG. 11B and FIG. 12A.
  • the portion of the first surface 1410 being protected against ingress of fluids is equal to or less than the extent of the adhesion/encapsulation layer 1510/1310.
  • the extent of the adhesion layer 1510 in this cross- section may be less than the extent of the encapsulation layer 1310 - in some configurations, this may be advantageous as the edges of the adhesion layer 1510 are at least partially encapsulated 1310.
  • the extent of the adhesion layer 1510 may be larger than, equal to or less than the extent of the encapsulation layer 1310.
  • FIG. 11C and FIG. 12A An “equal to” portion of a substrate is depicted in FIG. 12B.
  • the extent of the adhesion layer 1510 is equal to or larger than the extent of the encapsulation layer 1310 - this may be advantageous in certain configurations as the surface area of encapsulant 1310 in direct contact with the surface 1410 of the substrate 1400 is greatly reduced. In some cases, this surface area may be substantially zero, further reducing the possibility of fluid ingress.
  • a “substantially zero” embodiment is depicted in FIG. 11C and a portion of a substrate depicted in FIG. 12B.
  • FIG. 11B depicts another implantable electrical or electronic device 1101. It is the same as the implantable electrical device 1100 depicted in FIG. 11 A, except for further comprising:
  • a second biocompatible encapsulation layer 1320 comprising a polydimethylsiloxane (PDMS) rubber
  • a second adhesion layer 1520 comprising a ceramic material, disposed between the second planar surface 1420 and the second encapsulation layer 1320.
  • the second adhesion layer 1520 is further configured and arranged to conform to the second surface 1420 - in other words, it is a conformal layer.
  • the second adhesion layer 1520 and the second encapsulation layer 1320 are configured and arranged to resist the ingress of fluids from a human or animal body into at least a portion of the second surface 1420. The configuration and arrangement are further described below.
  • the second encapsulation layer 1320 may be substantially identical, similar to a high degree or substantially different to the first encapsulation layer 1310.
  • the second adhesion layer 1520 may be substantially identical, similar to a high degree or substantially different to the first adhesion layer 1510.
  • first surface 1410 and second surface 1420 are depicted as opposite faces of a substrate in FIG. 11B, other combinations are possible, such as:
  • first surface 1410 and second surface 1420 being substantially perpendicular to each other.
  • FIG. llC depicts a further implantable electrical or electronic device 1102. It is the same as the implantable electrical device 1100 depicted in FIG. 11 A, except in this cross-section:
  • the substrate 1400 comprises four protected surfaces, each surface being protected by a further adhesion layer 1500 and a further encapsulation layer 1300;
  • the extent of the further adhesion layer 1500 is larger than the extent of substrate 1400 for each protected surface;
  • the extent of the further encapsulation layer 1300 is larger than the extent of the substrate 1400 for each protected surface
  • the extent of the further adhesion layer 1500 is less than the extent of the encapsulation layer 1300 for each protected surface.
  • the further encapsulation layer 1300 comprises the first 1310 and second 1320 encapsulation layers depicted in FIG. 11B.
  • the further adhesion layer 500 comprises the first 1510 and second 1520 adhesion layers depicted in FIG. 11B.
  • the substrate 1400 depicted in FIG. llC comprises the protected portions of the first 1410 and second 1420 surfaces depicted in FIG. 11B.
  • the substrate 1400 depicted in FIG. 11C comprises two or more further protected surfaces, adjacent to such a protected first or second surface.
  • the further encapsulation layer 1300 of FIG. 11C may be substantially identical, similar to a high degree or substantially different to the first encapsulation layer 1310 depicted in FIG. 11 A or 11B.
  • the further encapsulation layer 1300 of FIG. 11C may be substantially identical, similar to a high degree or substantially different to the second encapsulation layer 1320 depicted in FIG. 11B.
  • the further adhesion layer 1500 of FIG. 11C may be substantially identical, similar to a high degree or substantially different to the first adhesion layer 1510 depicted in FIG. 11A or 11B.
  • the further adhesion layer 1500 of FIG. 11C may be substantially identical, similar to a high degree or substantially different to the second adhesion layer 1520 depicted in FIG. 11B.
  • the further embodiment 1102 may be advantageous because:
  • the portion of the surfaces of the substrate 1400 being protected against ingress of fluids is less than the extent of the further encapsulation layer 1300;
  • the surface area of encapsulant 1300 in direct contact with a surface of the substrate 1400 is close to or substantially zero.
  • FIG. 10 depicts a cross-section through the test sample 1130
  • Interdigitated capacitors (IDC) 1230 were used to evaluate encapsulation performance - approximately 600nm of Pt (Platinum) was sputtered on top of a 1 pm (1 micron) thick plasma enhanced chemical vapor deposition (CVD) Si02 layer 1435 with an intermediate lOnm titanium adhesion layer. More details on these IDC 1230 are found in “Silicone rubber encapsulation for an endoscopically implantable gastrostimulator”, Lonys, Vanhoestenberghe, Julemont, Godet, Delplancke, Mathys and Nonclercq, Med. Biol. Eng. Comput. 53 319-29, 2015. The Si02 layer 1435 was provided on a silicon substrate 1430.
  • Atomic layer deposition is a coating process that may be used to create nm-thick conformal coatings.
  • the ALD coating was applied using the PICOSUN® R-200 Advanced ALD reactor under reduced pressure (N2 atmosphere) of about 1 mbar (lhPa).
  • the R-200 Advanced from Picosun Oy, Finland, provides very high quality ALD film depositions. It is suggested by the manufacturer as suitable for depositions including: A1203, Ti02, Si02, Ta205, Hf02, ZnO, Zr02, AIN, TiN, metals such as Pt or Ir.
  • It comprises a remote microwave plasma generator, with adjustable 300 - 3000 W power, 2.45 GHz frequency, mounted to the loading chamber and connected to the reaction chamber. Up to twelve sources with six separate inlets may be used - seven if the plasma option is chosen.
  • the precursor sources may comprise liquid, gaseous and/or solid chemicals. Precursors may also include ozone and/or plasma.
  • the remote plasma option allows deposition of metals with a greatly reduced risk of short-circuiting and/or plasma damage.
  • the processing temperature may in general be 50 - 500°C. Plasma may generally be used up to approximately 450°C, or up to approximately 650 °C with a heated sample holder.
  • It comprises a hot-wall and substantially separate inlets and instrumentation providing a relatively low particle (or substantially particle-free) processing adaptable on a wide range of materials on wafers, 3D objects, and nanoscale features. It provides a high degree of uniformity, even on porous, through-porous, high aspect ratio (up to 1:2500), and nanoparticle samples using their proprietary PicoflowTM diffusion enhancer. This enhancer provides a protective gas flow in an intermediate space to greatly reduce back-diffusion of the plasma species.
  • a suitable ALD process for forming a monolayer comprising a first and second element, may comprise:
  • PicohotTM 300 source system allows source heating up to 300 degr. C, and is suggested by the manufacturer to be suitable with source chemicals having a vapor pressure of at least 2 mbar at source temperature.
  • the PicosolutionTM 600 source system allows liquid precursors to be used, and are suggested by the manufacturer to be suitable with source chemicals having a vapor pressure of at least 10 mbar at source temperature.
  • Thermal ALD-processes at 200 degr. C were applied with layer-by-layer deposition method where the two different precursor materials (separated by N2 purge to remove surplus molecules from the reaction space) were used to build up a Hf02 (hafnium dioxide) coating 1530 - this is depicted in FIG. 10 as a coating 1530 substantially covering the external surfaces of the substrate 1430, 1435 and the IDC sensors 1230.
  • Hf02 hafnium dioxide
  • An optional stabilization time of approximately 90 minutes was used at 200 degr. C. Ten layers of approximately 5nm were applied to provide an ALD layer of approximately 50nm.
  • ALD may be advantageous to create an ultra-thin conformal coating with low defects and/or reduced pinhole formation.
  • the deposition temperature for ALD may be kept below 200°C which is advantageous for devices incorporating sensitive metallization and/or polymers.
  • Samples were encapsulated with a layer comprising a substantially biocompatible PDMS (MED2-6215, NuSil Carpinteria, USA) 1330.
  • a substantially biocompatible PDMS MED2-6215, NuSil Carpinteria, USA
  • nusil.com/product/med-6215_optically-clear-low-consistency-silicone- elastomer From nusil.com/product/med-6215_optically-clear-low-consistency-silicone- elastomer:
  • MED-6215 is an optically clear, low consistency silicone elastomer. It is provided as two-parts which are solvent free and have a relatively low viscosity. It cures with heat via addition-cure chemistry. The mix ratio is 10:1 (Part A: Part B).
  • MED-6215 is considered substantially biocompatible - the manufacturer suggests that it may be used in human implantation for a period of greater than 29 days.
  • silicone primer Nu-Sil MED 1-161 as a primer to further improve adhesion of MED-6215 to various substrates including: metals (such as stainless steel, steel, copper and aluminum), ceramic materials, rigid plastics, and other silicone materials.
  • MED-6215 is available in medical grade - in other words, substantially biocompatible and suitable for use in a medical implantable device. This is realized by ensuring all raw materials, intermediates, and finished products (for Medical Grade) are manufactured with applicable GMP and/or appropriate regulatory standards: cGMP 21 CFR ⁇ 820 (Device), cGMP 21 CFR ⁇ 210-211 (Drug/API) and ISO 9001.
  • a dip-coating process was used for the encapsulation.
  • the average relatively low viscosity for example, 4000 to 7000 cP (mPas) appears to have allowed the PDMS to more easily flow over the sample.
  • the thickness of the PDMS 1330 was estimated to be between 50 and 200 pm (micron).
  • the lifetime reliability of ALD coatings may depend on factors such as the conformality and adhesion of the layer, and its stability in ionic media. This was measured using the IDC’s impedance after an extended soak test.
  • PBS phosphate buffered saline
  • Electrochemical impedance spectrometry was carried out to evaluate the performance of the ALD and ALD-PDMS coatings using the methods described in “Apparatus to investigate the insulation impedance and accelerated life-testing of neural interfaces”, Donaldson, Lamont, Shah Idil, Mentink, Perkins, J. Neural Eng, 2018, 10.1088/1741 -2552/aadeac.
  • Measurements used a Solartron Modulab with a potentiostat in combination with a frequency response analyzer. Measurements were performed in a two-cell electrode configuration between the combs of the IDC structure. A Faraday cage was also used.
  • FIG. 8 A and 8B show the EIS results 1700, 1710 for three samples.
  • FIG. 8 A depicts Bode plots 1700, with impedance magnitude along the vertical (Y) axis from 10 1 to 10 11 ⁇ Z ⁇ Ohm, and frequency along the horizontal (X) axis from 10 2 to 10 5 Hz: a bare IDC with exposed Pt metal 1701, forming an approximately straight line from approx. 10 2 , 5xl0 6 to 10 4 , 10 2 , followed by a further straight line to 10 5 , 10 2 ;
  • FIG. 8B depicts Bode plots 1710, with phase along the vertical (Y) axis from 0 to -90 degrees, and frequency along the horizontal (X) axis from 10 2 to 10 5 Hz:
  • the phase 1711 appears to be relatively constant at approximately -80 degr.
  • the polarization resistance appears to be dominant, resulting in a phase of approximately -20 degr. It is believed that this indicates the metal fully exposed to an electrolyte.
  • the ALD-coated IDC 1702, 1712 appeared to show relatively higher impedance values - this suggests a more capacitive behavior across the frequency range. This capacitance is believed to be caused by the Pt metal and electrolyte being separated by an ALD layer, which acts as a dielectric. It is believed that a fully conformal coating on the metal, or high resistance to fluid ingress, would result in a substantially capacitive behavior in the EIS results 1700, 1710.
  • the impedance 1703 and phase 1713 results show a substantially capacitive behavior across substantially the whole frequency range, with phase results 1713 close to approximately -90°. It is believed that any delamination or cracking of the ALD layer may expose more metal to the electrolyte, possibly resulting in a substantially lower impedance and phase angle that is more significantly seen in the lower frequency regions ⁇ 1 O 1 Hz.
  • a comparison between the ALD 1702, 1712 and ALD-PDMS bilayer 1703, 1713 shows an approximately two orders of magnitude higher impedance value 1703 for the bilayer encapsulated IDC 1703, 1713.
  • the phase results 1713 show a substantially more capacitive behavior.
  • PDMS metal areas exposed due to ALD defects are also encapsulated with the PDMS, with a specific resistance of approximately 10 15 Ohm. cm. It is believed that any significant delamination of the PDMS from ALD would allow water condensation, resulting in one or more conductive paths between the combs. This may result in a lower impedance and phase angle more significantly seen in the lower frequency regions of approximately ⁇ 10 1 Hz.
  • FIG. 8C and 8D show the adhesion evaluation results 1720, 1730 for two ALD samples and two ALD-PDMS samples over the four hundred and fifty days of soaking.
  • FIG. 8C depicts adhesion evaluation 1720, with impedance magnitude along the vertical (Y) axis from 0 to 10 11 ⁇ Z ⁇ Ohm, and Time along the horizontal (X) axis from 0 to 16 months:
  • FIG. 8D depicts adhesive evaluation 1730, with phase along the vertical (Y) axis from -30 to -90 degrees, and Time along the horizontal (X) axis from 0 to 16 months: - a first IDC 1732a coated with Hf02 ALD, forming an approximately straight line from 0, -70 to 16, -65;
  • Pt is widely used as for conductors and/or electrode regions due to its high degree of biocompatibility and stability.
  • long term stability may be reduced in conventional systems due to the relatively weak adhesion of encapsulants, such as PDMS, parylene and epoxy to Pt.
  • an adhesion layer comprising one or more ceramic materials may be advantageous.
  • an Hf02 ALD layer with an average thickness of approximately 25nm to lOOnm, preferably approximately 50nm, may provide a substantially stable intermediate adhesion layer between Pt and the PDMS.
  • a relatively high degree of adherence was also measured between the Hf02 layer and the Si02 substrate - in particular between the Pt forks.
  • a substrate comprising other materials may thus be provided with a layer of Si02 and/or Pt to improve adhesion to the Hf02 ALD layer.
  • the ALD-PDMS bilayer of an encapsulation layer 1330 and adhesion layer 1530 appears particularly advantageous:
  • the Hf02 ALD adhesion layer appeared to show a significantly higher stability in ionic media, thereby, providing relatively longer resistance against delamination or water permeation through the PDMS encapsulation.
  • a PDMS having a relatively low average viscosity for example 4000 to 7000 cP (mPas)
  • mPas average viscosity
  • PDMS-type materials are, in general, highly suitable for implantation due to their relatively high degree of biocompatibility. By appropriate selection and processing, many PDMS-type materials may be configured and arranged to be substantially biocompatible.
  • Polymeric materials comprised in the substrate 1400 are preferably selected for suitability to be flexible, and to comprise the one or more electrical conductors 1210.
  • the polymeric substrate materials Preferably, the polymeric substrate materials have a high degree of biocompatibility and durability.
  • Suitable polymer materials for being comprised in substrate 1400 include those mentioned above for conformable substrates in relation to FIG. 1 to FIG. 4.
  • a polyimide, Parylene C, SU-8, an LCP, a polyurethane, or any combination thereof may be used.
  • the first and/or second surface 1410, 1420 comprise a significant amount of one or more Liquid Crystal Polymers (LCP’s).
  • LCP Liquid Crystal Polymers
  • the first and/or second surface 1410, 1420 may substantially consist of one or more LCP’s.
  • the first and/or second surface 1410, 1420 may essentially consist of one or more LCP’s.
  • Thickness Um (micron) 25, 50, 100 12, 25, 50
  • the substrate 1400 for example comprising an LCP, has a Young’s modulus in the range 2500 to 3600 MPa (2.5 to 3.6 GPa).
  • the substrate 1400 may further comprise one or more electrical or electronic components configured to receive energy when electrical energy is applied to the one or more electrical conductors 1210.
  • they may be inductively- coupled, capacitively-coupled or directly connected.
  • substrates comprising significant amounts of one or more LCP’s as PCB-techniques may be used.
  • a bio-compatible metal such as gold or platinum is used.
  • one or more encapsulation layers 1310, 1320 and one or more adhesion layers 1510, 1520 are configured and arranged to resist the ingress of fluids to at least a portion of one or more surfaces 1410, 1420 proximate the one or more components.
  • the one or more components may be an active component, a passive component, an electronic component, an integrated circuit (IC), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), an analog component, a digital component, a surface-mount device (SMD), a through-hole package, a chip carrier, a pin grid array, a fat package, a small outline package, a chip scale package, a ball grid array, a small-pin-count package, a flexible silicon device, a thin-film transistor (TFT), and any combination thereof.
  • IC integrated circuit
  • ASIC application- specific integrated circuit
  • FPGA field-programmable gate array
  • an analog component a digital component
  • SMD surface-mount device
  • TFT thin-film transistor
  • the one or more electrical components may be configured and arranged to: resist, store charge, induct, sense, stimulate, amplify, process data, detect, measure, compare, switch, time, store data, count, oscillate, perform logic, add, generate stimulation pulses, and any combination thereof.
  • the substrates 1400 may be further configured and arranged to have a degree of conformance as described above. They may be foil-like (or film-like) and follow the contours of underlying anatomical features very closely by being flexible. Very thin foil like substrates 1400 have the additional advantage that they have increased flexibility.
  • An implantable electrical device 1100, 1101 as described herein may be comprised in an implantable medical device 1110, 1111.
  • a medical device 110, 1111 may be configured and arranged to provide a degree of sensing, stimulation, data processing, detection or measurement, data storage, oscillation, logic performance, stimulation pulses generation, or any combination thereof.
  • implantable stimulators 101, 102, 103, 104, 105 may comprise an implantable electrical device 1100, 1101, 1102.
  • an improved implantable medical device 1110 may be provided by modifying the implantable device 1100, depicted in FIG. 11 A. It is the same as the implantable electrical device 1100 depicted in FIG. 11 A, except in this cross- section:
  • the substrate 1400 comprises three protected surfaces, each surface being protected by a further adhesion layer 1500 and a further encapsulation layer 1300.
  • the three protected surfaces comprise two opposite protected surfaces and a further adjacent surface;
  • the extent of the further adhesion layer 1500 is less than the extent of the substrate 1400 for the two opposite protected surfaces.
  • the extent of the further adhesion layer 1500 is greater than the extent of the substrate 1400 for the third adjacent protected surface;
  • the extent of the further encapsulation layer 1300 is less than the extent of the substrate 1400 for the two opposite protected surfaces.
  • the extent of the further encapsulation layer 1300 is greater than the extent of the substrate 1400 for the third adjacent protected surface;
  • the extent of the further adhesion layer 1500 is less than the extent of the further encapsulation layer 1300 for each protected surface.
  • the further encapsulation layer 1300 comprises the first 1310 and second 1320 encapsulation layers depicted in FIG. 11B.
  • the further adhesion layer 1500 comprises the first 1510 and second 1520 adhesion layers depicted in FIG. 11B.
  • the substrate 1400 depicted in FIG. 12A comprises a further protected surface, adjacent to such a protected first or second surface.
  • the further encapsulation layer 1300 of FIG. 12A may be substantially identical, similar to a high degree or substantially different to the first encapsulation layer 1310 depicted in FIG. 11 A or 1 IB.
  • the further encapsulation layer 1300 of FIG. 12A may be substantially identical, similar to a high degree or substantially different to the second encapsulation layer 1320 depicted in FIG. 11B.
  • the further adhesion layer 1500 of FIG. 12A may be substantially identical, similar to a high degree or substantially different to the first adhesion layer 1510 depicted in FIG. 11 A or 11B.
  • the further adhesion layer 1500 of FIG. 12A may be substantially identical, similar to a high degree or substantially different to the second adhesion layer 1520 depicted in FIG. 11B.
  • the medical device 1110 further comprises:
  • one or more stimulation electrodes 1220 configured and arranged to transmit energy to human or animal tissue when electrical energy is applied to the one or more electrical conductors 1210. For example, they may be inductively-coupled, capacitively- coupled or directly connected. In the example depicted, the one or more stimulation electrodes 1220 are directly connected to the one or more electrical conductors 1210. In many neurostimulation applications, a plurality of electrodes 1220 may be required.
  • Electrodes 200, 400 may be identical, similar or different to the electrodes 200, 400 described above in relation to FIG. 1 to FIG. 4.
  • one or more sensors 1230 may similarly be provided - such sensors 1230 are configured to be provided electrical signals and/or data to the one or more electrical conductors 1210. For example, they may be inductively- coupled, capacitively-coupled or directly connected. If a multilayer substrate with electrical interconnections is provided, a high degree of customization is possible. For example, allowing direct measurements of parameters relevant for operation, such as humidity, temperature, electrical resistance and electrical activity.
  • one or more electrodes 1220 are configured and arranged to operate as a ground or return electrode - this may be one of the existing electrodes or one or more further electrodes as described above for the first 200a, 200b and second 400a, 400b electrodes described above in relation to FIG. 1 to FIG. 4.
  • a stimulation electrode 1220 and/or a tissue sensor is preferably not completely covered by an encapsulation layer 1300 and/or an adhesion layer 1500 as a sufficiently high degree of electrical connection or exposure to the implant environment are required for their function.
  • at least part of a stimulation electrode 1220 and/or tissue sensor is masked during the encapsulation process to provide a conductive surface towards tissue. Additionally or alternatively, portions of the device may not be encapsulated.
  • FIG. 12A depicts a device 1110 where substantially all of a stimulation electrode 1220 is substantially not covered.
  • a portion of the substrate 1400 is substantially not covered, providing a device 1110 with a substantially encapsulated portion and a substantially unencapsulated portion with one or more electrodes 1220.
  • the extent of the further adhesion layer 1500 in this cross-section for the two opposite surfaces is less than the extent of the further encapsulation layer 1300 for these surfaces - this may be advantageous as the edges of the further adhesion layer 1500 are at least partially encapsulated 1300.
  • Applying this encapsulation to the implantable stimulators described above in relation to FIG. 1 and FIG. 4 generally provides a substantially unencapsulated portion with one or more electrodes 200, 400, and a substantially encapsulated portion comprising a pulse generator 500.
  • FIG. 12B depicts a further embodiment of a medical device 1111. More particularly, it depicts a cross-section through a portion of the substrate 1400 comprising one or more electrode 1220.
  • the further medical device 1111 is the same as the device 1110 depicted in FIG. 12A except, in general, in this cross-section:
  • the substrate 1400 comprises four protected surfaces, each surface being protected by a further adhesion layer 1500 and a further encapsulation layer 1300;
  • the extent of the further adhesion layer 1500 is larger than the extent of substrate 1400 for each protected surface;
  • the extent of the further encapsulation layer 1300 is larger than the extent of the substrate 1400 for each protected surface
  • the extent of the further adhesion layer 1500 is less than the extent of the encapsulation layer 1300 for each protected surface.
  • the further adhesion layer 1500 has been applied to the surface of the substrate 1400 adjacent to the stimulation electrodes 1220 and also applied to edge portions of the surface of the electrodes 1220. This may provide additional protection against ingress at any interface between the electrode 1220 and the substrate 1400;
  • the further encapsulation layer 1300 has been applied to the surface of the substrate 1400 adjacent to the stimulation electrodes 1220. However, is not significantly applied to edge portions of the surface of the electrodes 1220.
  • the extent of the further adhesion layer 1500 is approximately the same as the extent of the further encapsulation layer 1300.
  • Applying this encapsulation to the implantable stimulators described above in relation to FIG. 1 and FIG. 4 generally provides a substantially encapsulated portion in which “a part” of the one or more electrodes 200, 400, and a substantially encapsulated portion comprising a pulse generator 500.
  • the extent of the further encapsulation layer 1300 in this cross-section at an edge portion of one or more electrodes 1220 is greater than the extent of the further adhesion layer 1500 - in some configurations, this may be advantageous as the edges of the further adhesion layer 1500 are at least partially encapsulated 1300.
  • the one or more stimulation electrodes 1220 and/or sensor are preferably comprised in a surface, configured and arranged to provide a tissue interface.
  • the electrodes 1220 are relatively thin (for example, when the substrate conforms to a substantially planar surface, having an extent along a transverse axis approximately perpendicular to a longitudinal axis of the substrate, of 20 to 50 microns or less. Thinner electrodes may be also be used to further increase the degree of conformability, for example 1 micron or less), and attached to (or at least partially embedded in) the surface.
  • substrates comprising significant amounts of one or more LCP’s as PCB/metallization-techniques may be used to provide conductive regions, which may be configured and arranged to be electrodes 1220 and/or sensors 1230.
  • a conductive material is preferably used such as gold, platinum, platinum black, TiN, IrCh, iridium, and/or platinum/iridium alloys and/or oxides.
  • Conductive polymers, such as Pedot may also be used.
  • bio compatible conductive materials are used.
  • thicker metal layers are generally preferred over thinner metal layers for electrodes 1220 because they can be subjected to bodily substances that may dissolve the metal.
  • thicker metal layers typically increase rigidity (reduce conformability) proximate the thicker layer.
  • MED2-4213 is a two-part, translucent, thixotropic, a relatively high extrusion rate, a relatively high tear strength, a relatively fast-cure silicone adhesive. It is also substantially free of tin (Sn), reducing the requirement for atmospheric moisture to cure. It also does not comprise significant amounts of curing byproducts, such as acetic acid or methyl alcohol.
  • MED2-4213 is considered substantially biocompatible - the manufacturer suggests that it may be used in human implantation for a period of greater than 29 days.
  • Typical chemical and physical properties include: Uncured:
  • first (1310) and/or second (1320) encapsulation layers have/has a tensile strength in the range 6 to 8 MPa.
  • NuSil suggests that in many bonding applications (for a substrate comprising Aluminum, Glass, PMMA, Silicone) the use of a silicone primer to improve suitable adhesion is not required.
  • primer is suggested by the manufacturer when adhering to substrates comprising Polyetherimide, PEEK, Plastic, Polycarbonate, Polyimide, Polysulphone, Polyurethane, and Stainless steel.
  • - TYPE 2 an LCP 2-layered laminated substrate with ALD coating on one side.
  • a process with relatively few steps may be based around overmoulding electronics that are directly mounted on a substrate (here LCP).
  • LCP substrate
  • the PDMS used may need to adhere sufficiently well to surfaces such as:
  • Si-substrate is one of the relevant interfaces when using bare-die components. Bare die integrated circuits are often made from a wafer or substrate, that is a thin slice of crystalline silicon semiconductor. To make a bare-die component, this material undergoes many microfabrication processes to become an integrated circuit, but one side will always be the raw material that was used, most often crystalline silicon. Relevant interfaces include:
  • ACF Anisotropic conductive film
  • the substrate - in this case, a substrate comprising significant amounts of LCP.
  • TYPE 1 LCP substrates were prepared using one or more of the following process steps: a) Providing a substrate: these substrates were substantially planar sheets of LCP with an average thickness of approximately 0.150 mm. The substrate comprised three layers; two 0.050mm layers of ULTRALAM® 3908, separated by one 0.050mm layer of ULTRALAM 3850.
  • ULTRALAM® 3908 LCP is available from Rogers Corporation (www.rogerscorp.com) and may be used as a bonding medium (adhesive layer) between copper, other LCP materials and/or dielectric materials. It is characterized by low and stable dielectric constant. It has a relatively low modulus, allowing relatively easy bending for flex applications, and relatively low moisture absorption.
  • ULTRALAM® 3850 LCP may be used with one or more layers of ULTRALAM® 3850 LCP to create substantially adhesive-less substantially all-LCP multi-layer substrates.
  • Flammability VTM-0 UL-94 ULTRALAM® 3850 is available from Rogers Corporation (www.rogerscorp.com) and is a relatively high-temperature resistant LCP. It may be provided as a double copper clad laminate for use as laminate circuit materials. The manufacturer suggests these products for use as a single layer or a multilayer substrate. ULTRALAM 3850 circuit materials are characterized by a relatively low and stable dielectric constant, and dielectric loss. It has a relatively low modulus, allowing relatively easy bending for flex applications, and relatively low moisture absorption.
  • ULTRALAM® 3908 LCP may be used with one or more layers of ULTRALAM® 3908 LCP to create substantially adhesive-less substantially all-LCP multi-layer substrates.
  • Typical values for physical and chemical properties of ULTRALAM® 3850 LCP include:
  • Flammability VTM-0 UL-94 TYPE 1 LCP substrates were further prepared using one or more of the following process steps: bl) an optional pre-cleaning of at least a portion of the substrate using IPA, followed by drying. Another suitable alcohol may also be used.
  • the ALD coating was applied using the PICOSUN® R-200 Advanced ALD reactor described above. It was applied at a temperature substantially lower than the melting temperature of the LCP. For these TYPE 1 LCP substrates, it was applied at approximately 125 degr C after an optional stabilization time of approximately 90 minutes.
  • this step was omitted for some of the samples (in other words, the PDMS was applied directly to the LCP).
  • UV 03 ozone plasma cleaning is suitable for dry, non-destructive atomic cleaning and removal of organic contaminants. It uses intense 185 nm and 254 nm ultraviolet light. In the presence of oxygen, the 185 line produces Ozone and while the 254 line excites organic molecules on the surface. This combination drives the rapid destruction and decimation of organic contaminants.
  • a PDMS coating of approximately 500 um to 1000 um of MED2-4213 was applied on top of the ALD coating.
  • a syringe was filled with MED2-4213, and mixed & degassed at relatively high speed (2500 rpm) for three minutes. It was cured at 150 degr C for lOmin and post-cured at 80 degr C for 24 hours.
  • the extent of the PDMS coating was less than the extent of the ALD coating, whereby the ALD coating was exposed (not covered by encapsulant) close to the edge of the substrate.
  • the substrate was placed on the PTFE (polytetrafluorethylene)-coated pre-heated plate, and a weight was pressed on top of it.
  • the samples were soaked in a PBS solution at 60 degr C for 1 day, 1 week, and 4 weeks, and the Peel -test was repeated to determine a second degree of delamination.
  • the PDMS can be removed relatively easily from the substrate
  • the PDMS can be removed relatively easily in some areas, but sticks relatively well in other areas
  • the PDMS does not substantially delaminate
  • PBS Phosphate-buffered saline
  • PBS Phosphate-buffered saline
  • the buffer helps to maintain a constant pH.
  • the osmolarity and ion concentrations of the solutions are selected to match those of the human body (isotonic).
  • Samples 1.1 in general, PDMS has a low degree of adhesion to LCP
  • PDMS had a low degree of adhesion to LCP without any adhesion layer (samples 1.1).
  • An A1203/Hf02 multilayer ALD layer with a total average thickness of approximately 50nm to 200nm, preferably approximately lOOnm, may provide an advantageous intermediate adhesion layer between LCP and the PDMS polymer.
  • TYPE 2 LCP laminated substrates were prepared using one or more of the following process steps: a) Providing a substrate: these substrates were laminated sheets of LCP, with an average thickness of approximately 0.110 mm.
  • the substrate comprised four layers; one outer layer of copper connection pads, one 0.050 mm layer of ULTRALAM® 3850, one inner layer of one or more copper conductors, and one 0.025mm layer of ULTRALAM 3908: al) an approximately 50um-thick sheet of LCP ULTRALAM® 3850, clad on a first surface with a first copper layer. This first copper layer was approximately 18um-thick.
  • the first copper layer was configured and arranged to form copper connection pads, for example by masking and etching, which may be considered to be comprised in an outer surface of the laminated substrate; a2) the ULTRALAM® 3850 was further clad with a further copper layer.
  • This second layer was approximately 18um-thick.
  • it may be configured and arranged to form one or more conductors, for example by masking and etching, which may be considered to be comprised in an inner surface of the laminated substrate. If no inner conductors are required, the further copper layer may be omitted or completely removed. ; a3) an approximately 25um -thick sheet of LCP ULTRALAM® 3908, bonded to the inner surface of the ULTRALAM® 3850 layer, and further bonded to the one or more conductors.
  • the laminated sheets may be substantially planar.
  • an adhesion coating bl) an optional pre-cleaning of at least a portion of the substrate using IPA, followed by drying. Another suitable alcohol may also be used.
  • b2) using ALD a coating was applied to an outer surface of the substrate - in this case a surface comprising ULTRALAM® 3908 LCP. It was not the outer surface of the substrate comprising one or more connection pads.
  • Ten alternating layers of approximately 5nm A1203 and of approximately 5nm Hf02 resulted in an approximately lOOnm multilayer.
  • the ALD coating was applied using the PICOSUN® R-200 Advanced ALD reactor described above. It was applied at a temperature substantially lower than the melting temperature of the LCP.
  • Option 2 exposing the ALD surface to a plasma comprising 02.
  • Oxygen plasma refers to any plasma treatment performed while actively introducing oxygen gas to the plasma chamber. Oxygen plasma is created by utilizing an oxygen source on a plasma system.
  • ozone (03) may be used.
  • C used with PTFE-coated molds under a relatively low vacuum for example 800 - 900 Pa (8 to 9 mbar) -vacuum centrifugal casting was used to reduce the risk of air inclusion in the PDMS.
  • applying a vacuum may be advantageous in improving the application to an adhesion coating of the encapsulation of a PDMS having an average viscosity in the range 55000 to 100000 cP (mPas) for a significant time period.
  • the extent of the PDMS coating was approximately the same as the extent of the ALD coating. After removing the Kapton tape, a strip of approximately 10mm wide was provided where the PDMS was not attached to the ALD coating. e) Performing further processing: the coated substrate of approximately 100x75mm area was cut into 7 pieces of approximately 100x10mm for Peel -testing. Each piece had an area of approximately lOxlOmm without the PDMS coating at is edge due to Kapton tape removal.
  • Peel -test according to ASTM D1876 was adapted for testing the TYPE 2 LCP or laminated substrates). A Peel-tester was used to measure the lamination force.
  • FIG. 9 depicts a graph 1750 comparing the average pull force under dry (not soaked) conditions with the average pull forces after 24 hours of soaking at 60 degr. C in PBS.
  • the samples of LCP were coated with PDMS using different processes.
  • Average peel force is plotted along the vertical (Y) axis from 0 to 18 N, and the results are indicated for the different samples along the horizontal (X) axis. To simplify interpretation, the order of the samples chosen is numerical: from left to right, samples 2.2, 2.2, 2.3, 2.4 and 2.5.
  • each bar For each sample, the vertical length of each bar indicates the average peel force in Newtons (N). For each bar, an “I” shaped line is also depicted to indicate the variation measured in the pull force values used to determine the average. For each sample, an unfilled bar is depicted on the left-hand side showing the average pull force under dry conditions, and a hatched bar on the right-hand side showing the average pull force after 24 hours of soaking at 60 degr. C in PBS.
  • an unfilled bar 1762a is depicted of approx. 13N, with an average degree of variation.
  • a hatched bar 1762b is depicted of approx. 14N, with a relatively high degree of variation.
  • an unfilled bar 1763a is depicted of approx. 5N, with a relatively small degree of variation.
  • a hatched bar 1763b is depicted of approx. 7N, with an average degree of variation.
  • an unfilled bar 1764a is depicted of approx. 7N, with a relatively small degree of variation.
  • a hatched bar 1764b is depicted of approx. 7.5N, with an average degree of variation.
  • an unfilled bar 1765a is depicted of approx. 8N, with a relatively small degree of variation.
  • a hatched bar 1765b is depicted of approx. 8N, with an average degree of variation.
  • Samples 2.2 substrates with a primer appeared to have a relatively high degree of adhesion (approx. 13N - 1762a - compared to approx. 4N - 1761a). During the test, some regions had a higher degree of adhesion, which resulted in the PDMS rupturing before peeling the samples completely. The average pull force after the soaking test appeared to be higher at approx. 14N - 1762b, but a relatively high degree of deviation was also observed.
  • Samples 2.3 by adding an ALD multilayer, specifically the Hf02-A1203 multilayer ending with Hf02, the degree of dry adhesion appeared improved (from approx. 4N - 1761a - to approx. 5N - 1763a). The results under dry conditions - 1763a - appears to have a very low degree of deviation. The average pull force after the soaking test appeared to be higher at approx. 7N - 1763b.
  • Samples 2.5 plasma activation appeared to further improve the degree of adhesion (approx. 8N - 1765a - compared to approx. 4N - 1761a).
  • the average pull force after the soaking test appeared to be approximately the same at 8N - 1765b.
  • MED- 166 from NuSil may be used. But it may be less-preferred in some uses. In particular, for implantable devices, it is advantageous to use materials that are significantly biocompatible and more preferably materials that are substantially biocompatible (have a high degree of biocompatibility). Although the manufacturer of MED-166 suggests that it is suitable for implantation for more than 29 days, primers are often epoxy adhesives which use volatile solvents. This may increase the risk of contamination due to insufficient evaporation and/or require additional process steps to ensure sufficient solvent removal.
  • An A1203/Hf02 multilayer ALD layer with a total average thickness of approximately 50nm to 200nm, preferably approximately lOOnm, may provide an advantageous intermediate adhesion layer between LCP and the PDMS polymer.
  • the ALD coating used improved adhesion of PDMS to LCP using materials suitable for use in an implantable electrical device.
  • an adhesion layer comprising a ceramic material may be advantageously used for a wide range of substrate materials.
  • first surface 1410 and/or second surface 1420 comprises a significant amount of a substance selected from the group comprising: a Liquid-Crystal Polymer (LCP), a polyimide, Parylene-C, SU-8, a polyurethane, or any combination thereof.
  • LCP Liquid-Crystal Polymer
  • polyimide polyimide
  • Parylene-C polyimide
  • SU-8 polyurethane
  • a substrate comprising other materials may thus be provided with a layer of such a material to improve adhesion to the Hf02 ALD layer.
  • adhesion may be improved by optionally or additionally applying a conformal coating to such a substrate, for example with an ALD process, applying a layer of Si02 (silicon dioxide).
  • PDMS is, in general, a silicone rubber, with siloxane as the basic repeating unit.
  • Methyl groups are substituted by a variety of other groups, for example, phenyl, vinyl or trifluoropropyl groups, depending on the type of PDMS, enabling the linkage of organic groups to an inorganic backbone.
  • an adhesion layer comprising a suitable ceramic material may be advantageously used for a wide range of substrate materials.
  • Suitable ceramic surfaces are relatively rich in hydroxyl groups. It is believed that the high degree of adhesions is due to oxygen in suitable PDMS-types can form strong bonds with the hydroxyl groups on the suitable ceramic surface. This may be chemical bonding, hydrogen-bridge bonding or some combination.
  • Suitable ceramics include:
  • SiC silicon carbide
  • oxides such as aluminum oxide (A1203);
  • SiNy or SiNxOy silicon
  • Si3N4 silicon nitride
  • adhesion of a PDMS may be improved where the ceramic material is selected from the group comprising: Hf02, A1203, Ta203, Ti02, and any combination thereof.
  • Diamond-like carbon may be advantageously used to improve adhesion.
  • Adhesion may be further improved by activating the surface of the ceramic layer - for example, by applying an alcohol, in particular ethanol; using a plasma comprising 03 (Ozone) and/or comprising 02; treating with a silane; or any combination thereof.
  • an alcohol in particular ethanol
  • a plasma comprising 03 (Ozone) and/or comprising 02
  • treating with a silane or any combination thereof.
  • An adhesion layer may be a bi-layer or multilayer, in which one or more layer may be configured and arranged for a relatively high degree of adhesion, and one or more layers may be configured and arranged for a relatively high degree of corrosion resistance (impermeability).
  • a layer comprising A1203 provides a relatively high degree of adhesion.
  • a layer comprising Hf02 provides a relatively high degree of corrosion resistance.
  • FIG. 5 and FIG. 6 also depict examples of nerves that may be stimulated using one or more suitably configured improved medical devices 1110, 1111, configured to provide neurostimulation to treat, for example, headaches, chronic headaches or primary headaches.
  • the substrate is substantially flexible (or conformable), it may conform better to the curved surfaces of the head and/or skull. This means that the comfort to the user of an implantable medical device 1110, 1111 may be increased by applying one or more of the features described above for improving conformance.
  • these will be the approximate locations 810, 820, 830, 840 for the one or more implantable medical devices 110, 111.
  • a separate stimulation device 110, 111 may be used for each implant location.
  • implant locations 810, 820, 830a/b, 840a/b are close together, or even overlapping a single stimulation device 110, 111 may be configured to stimulate at more than one implant location 810, 820, 830a/b, 840a/b.
  • a plurality of implantable medical devices 110, 111 may be operated separately, simultaneously, sequentially or any combination thereof to provide the required treatment.
  • FIG 7 depict further examples of nerves that may be stimulated using one or more suitably configured improved implantable medical devices 110, 111 to provide neurostimulation to treat other conditions.
  • one or more features that improve conformance may be applied to embodiments that are configured and arranged for improved encapsulation.
  • one or more features that improve encapsulation may be applied to embodiments that are configured and arranged for improved conformance.
  • one or more electrodes of the first type 200a, 200b, 1220 are comprised in the first surface 310, 1410 and one or more electrodes of the second type 400a, 400b, 1220 are comprised in the second surface 320, 1420; or
  • one or more electrodes of the first type 200a, 200b, 1220 are comprised in the first surface 310, 1410 and one or more electrodes of the second type 400a, 400b, 1220 are also comprised in the first surface 310, 1410; or
  • one or more electrodes of the first type 200a, 200b, 1220 are comprised in the second surface 320, 1420 and one or more electrodes of the second type 400a,
  • one or more electrodes of the first type 200a, 200b, 1220 are comprised in the second surface 320, 1420 and one or more electrodes of the second type 400a,
  • stimulators 100, 101, 102, 103, 104, 105, 1100, 1101, 1102 may be operated at a lower energy / lower power. This may be advantageous in applications where high frequency and/or burst stimulation is used.
  • High frequency operation may require more energy to be provided by the pulse generator 500.
  • energy / power is critical, such as, in a non limiting example, if an increased operating lifetime is desired from a power source for the pulse generator 500), any reduction in required power may be advantageous.
  • High frequency operation may be considered as generating electrical stimulation pulses with a frequency of 1000 Hz or more, preferably 1500 Hz or more, more preferably 2000 Hz or more, yet more preferably 2500 Hz or more.
  • experiments with burst stimulation have been performed such as Burst Occipital Nerve Stimulation for Chronic Migraine and Chronic Cluster Headache by Garcia-Ortega et al, Neuromodulation 2019; 22: 638-644, DOI: 10.1111/ner.12977.
  • the pulse generator 500 is further configured and arranged to generate electrical stimulation pulses in groups of stimulation pulses.
  • groups (or bursts) of stimulation pulses may comprise 2 to 10 pulses, more preferably 2 to 5 stimulation pulses.
  • Stimulation pulses in a group may have a repetition frequency of more than 500 Hz, typically 1000Hz or more. Groups may be repeated at more than 5 Hz, typically 40 Hz or more.
  • burst operation may require more energy to be provided by the pulse generator 500, and any reduction in required power may be advantageous.
  • the speed of charge-balance recovery may also increase with a lower impedance.
  • a relatively thin-foil substrate 300, 1400 stimulation between an electrode of the first type 200, 1220 comprised in one surface 310, 1410, 320, 1420 and an electrode of the second type 400, 1220 comprised in the other surface 310, 1410, 320, 1420, the current path in tissue is relatively short, reducing impedance.
  • a substrate 300, 1400 and stimulation between an electrode of the first type 200, 1220 comprised in one surface 310, 1410, 320, 1420 and an adjacent electrode of the second type 400, 1220 comprised in the same surface 310, 1410, 320, 1420 provide a relatively short path through tissue.
  • An implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 comprising:
  • a pulse generator 500 for generating one or more electrical treatment stimulation pulses
  • a conformable foil-like substrate 300, 1400 having a longitudinal axis 600 extending from the pulse generator 500 to a distal end of the substrate 300, 1400 the substrate 300, 1400 comprising one or more adjacent polymeric substrate layers, the substrate having a first 310, 1410 and second 320, 1420 planar surface;
  • an electrode array 200, 400, 1220 proximate the distal end having a first 200a, 200b, 1220 and second 400a, 400b, 1220 electrode comprised in the first 310, 1410 or second 320, 1420 surface, each electrode 200, 400, 1220 in operation being configurable for transferring treatment energy, in use, to and/or from human or animal tissue;
  • the implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 further comprising:
  • An implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 comprising:
  • a substrate 300, 1400 the substrate comprising a top surface 310, 1410 and a bottom surface 320, 1420;
  • a pulse generator 500 located along a first portion of the substrate 300, 1400, the pulse generator 500 being configured to generate at least one stimulation pulse;
  • an electrode array 200, 400, 1220 comprising at least two electrodes 200, 400, 1220 located along a second, conformable portion of the substrate 300, 1400;
  • a plurality of electrical interconnections 250, 1210 electrically coupling the pulse generator 500 to the at least two electrodes of the electrode array 200, 400, 1220, wherein the plurality of electrical interconnections 250, 1210 are positioned between the top 310, 1410 and bottom surfaces 320, 1420 of the substrate 300, 1400;
  • a maximum thickness of the substrate 300, 1400 in the second portion is equal to or less than 0.5 millimeters.
  • An implantable electrical device 100, 101, 102, 103, 104, 105, 1100, 1101, 1102 comprising:
  • a substrate 300, 1400 having a first surface 310, 1410 and one or more electrical conductors 250, 1210;
  • the substrate 300, 1400 is configured and arranged to be substantially flexible;
  • the first adhesion layer 1500, 1510, 1520 is configured and arranged to conform to the first surface 310, 1410 and comprises a ceramic material;
  • the first encapsulation layer 1300, 1310, 1320 comprises a polydimethylsiloxane (PDMS) rubber
  • the first adhesion layer 1500, 1510, 1520 and the first encapsulation layer 1300, 1310, 1320 are configured and arranged to resist the ingress of fluids from a human or animal body into at least a portion of the first surface 300, 1410.
  • - providing a substrate 300, 1400 having a first surface 310, 1410 and one or more electrical conductors 250, 1210;
  • a first biocompatible encapsulation layer 1300, 1310, 1320 comprising a polydimethylsiloxane (PDMS) rubber to at least a portion of the first adhesion layer 1500, 1510, 1520; wherein the first adhesion layer 1500, 1510, 1520 and the first encapsulation layer 1300, 1310, 1320 are configured and arranged to resist the ingress of fluids from a human or animal body into at least a portion of the first surface 310, 1410.
  • PDMS polydimethylsiloxane
  • An implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 comprising: a substrate 300, 1400 comprising a first surface 310, 1410 and a second surface 320, 1420, wherein a thickness of the substrate 300, 1400 is defined by the first 310, 1410 and second 320, 1420 surfaces; a pulse generator 500 being configured to generate at least one stimulation pulse; at least two electrodes 200, 400 1220 located along a conformable portion of the substrate 300, 1400; a plurality of electrical interconnections 250, 1210 electrically coupling the pulse generator 500 to the at least two electrodes 200, 400, 1220; an encapsulation layer 1300, 1310, 1320 at least partially covering the substrate (300, 1400); and an adhesion layer 1500, 1510, 1520 between the encapsulation layer 1300, 1310, 1320 and the substrate 300, 1400 in at least one location; wherein the thickness of the substrate 300, 1400 along the conformable portion is equal to or less
  • An implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 comprising: a substrate 300, 1400, the substrate 300, 1400 comprising a top surface 310, 1410 and a bottom surface 320, 1420; a pulse generator 500 located along a first portion of the substrate 300, 1400, the pulse generator 500 being configured to generate at least one stimulation pulse; at least two electrodes 200, 400, 1220 located along a second, conformable portion of the substrate 300, 1400; a plurality of electrical interconnections 250, 1210 electrically coupling the pulse generator to the at least two electrodes 200, 400, 1220; wherein the plurality of electrical interconnections 250, 1210 are positioned between the top 310, 1410 and bottom 320, 1420 surfaces of the substrate 300, 1400; an encapsulation layer 1300, 1310, 1320 covering at least part of the first portion of the substrate 300, 1400; and an adhesion layer 1500, 1510, 1520 between the encapsulation layer 1
  • An implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 according to any disclosed example, wherein the maximum thickness of the implantable stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 proximate the pulse generator 500 is equal to or less than 5 millimeters, or is equal to or less than 4 millimeters, is equal to or less than 3 millimeters, the thickness being determined by a perpendicular distance between corresponding points on outer planar surfaces.
  • the pulse generator 500 is located along a first portion of the substrate 300, 1400;
  • the electrode array 200, 400, 1220 is located along a second, conformable Liquid Crystal Polymer (LCP) portion of the substrate 300, 1400;
  • LCP Liquid Crystal Polymer
  • the plurality of electrical interconnections 250, 1210 are positioned on a first conformable LCP layer of the substrate 300, 1400 using electro-plating and/or a semiconductor deposition technique and at least one second conformable LCP layer of the substrate 300, 1400 is secured to the first layer so as to cover the plurality of electrical interconnections 250, 1210;
  • the encapsulation layer 1300, 1310, 1320 is biocompatible, covering the first portion and at least part of the second portion of the substrate 300, 1400, the encapsulation layer 1300, 1310, 1320 comprising Polydimethylsiloxane (PDMS) and having a tensile strength in the range 6 to 8 MPa;
  • PDMS Polydimethylsiloxane
  • one or more biocompatible adhesion layers 1500, 1510, 1520 conform to the substrate 300, 1400 and are positioned between the encapsulation layer 1300, 1310, 1320 and the substrate 300, 1400, wherein the one or more adhesion layers 1500, 1510, 1520 comprise a ceramic portion having an average thickness in the range of 25nm to 200nm that is applied using atomic layer deposition (ALD), and comprises at least one first layer comprising Ti02 and at least one second layer adjacent to the at least one first layer and comprising A1203;
  • ALD atomic layer deposition
  • the second portion of the substrate has a Young’s modulus in the range 2500 to 3600 MPa;
  • the one or more adhesion layers 1500, 1510, 1520 and the encapsulation layer 1300, 1310, 1320 are configured to resist ingress of fluids onto the substrate 300, 1400;
  • the thickness of the substrate 300, 1400 along the second portion is equal to or less than 0.2 millimeters
  • a thickness of the stimulator 100, 101, 102, 103, 104, 105, 1110, 1111 along the first portion is equal to or less than 4 millimeters;
  • the pulse generator 500 comprises an energy receiver configured to wirelessly receive energy from an energy transmitter.
  • first transverse axis 750 a second transverse axis
  • vagus nerve carotid artery, carotid sinus, phrenic nerve or hypoglossal stimulation

Abstract

L'utilisation de fils de neurostimulation dans la région craniofaciale est associée à l'érosion de la peau et à la migration du plomb. La forme cylindrique et l'épaisseur associée des conducteurs de l'état de la technique conduisent à l'érosion du plomb à travers la peau ou par le déplacement du fil de sorte que les électrodes ne couvrent plus les nerfs ciblés. Un stimulateur implantable 1001110 est pourvu d'un substrat 300, 1400 comprenant une partie adaptable avec un réseau d'électrodes, et un générateur d'impulsions 500. Une pluralité d'interconnexions électriques 250, 1210 sont positionnées entre les surfaces du substrat. La partie adaptable a une épaisseur égale ou inférieure à 0,5 millimètres. Facultativement, une ou plusieurs couches d'encapsulation 1300 peuvent être fournies. Facultativement, une ou plusieurs couches d'adhérence 1500 peuvent également être pourvues d'un matériau céramique. En fournissant un substrat pouvant être modelé plus facilement, des configurations de réseau d'électrodes plus compliquées peuvent être supportées, ce qui permet d'obtenir un degré de flexibilité plus élevé pour résoudre un mauvais alignement transversal et/ou longitudinal. L'utilisation d'un réseau d'électrodes implantable relativement mince permet d'augmenter le confort de l'utilisateur. L'au moins une couche d'adhérence améliore les performances de l'encapsulation.
EP20829652.5A 2019-12-04 2020-12-04 Stimulateur implantable doté d'un réseau d'électrodes et d'un substrat conformable Pending EP4069062A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US16/703,706 US11318319B2 (en) 2019-12-04 2019-12-04 Implantable stimulator with a conformable foil-like electrode array
NL2025268A NL2025268B1 (en) 2020-04-03 2020-04-03 An implantable electrical device comprising a substrate, encapsulation layer and adhesion layer
PCT/IB2020/061474 WO2021111371A1 (fr) 2019-12-04 2020-12-04 Stimulateur implantable doté d'un réseau d'électrodes et d'un substrat conformable

Publications (1)

Publication Number Publication Date
EP4069062A1 true EP4069062A1 (fr) 2022-10-12

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EP20829652.5A Pending EP4069062A1 (fr) 2019-12-04 2020-12-04 Stimulateur implantable doté d'un réseau d'électrodes et d'un substrat conformable

Country Status (6)

Country Link
EP (1) EP4069062A1 (fr)
JP (1) JP2023504499A (fr)
KR (1) KR20220113405A (fr)
CN (1) CN114760912A (fr)
AU (1) AU2020396453A1 (fr)
CA (1) CA3160396A1 (fr)

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CN116077829B (zh) * 2023-01-18 2023-12-15 微智医疗器械有限公司 植入装置和电刺激器以及电极电镀方法
CN116943035B (zh) * 2023-06-29 2024-02-23 江苏省人民医院（南京医科大学第一附属医院） 一种无导线自驱动心脏起搏辅助装置及其制备方法
CN117322862B (zh) * 2023-11-30 2024-03-12 微智医疗器械有限公司 一种颅内压传感器探头制作方法及颅内压传感器探头

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CN114760912A (zh) 2022-07-15
KR20220113405A (ko) 2022-08-12
CA3160396A1 (fr) 2021-06-10
AU2020396453A1 (en) 2022-06-09
JP2023504499A (ja) 2023-02-03

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